Instructions
Chassis / Fuel Tank / Fuel Service Procedures / DA-RM-04K001-01-001 - Remove/Install fuel tank
Preparation work
1.     
2.     
3.     
4.     
Care Point: Remove the left side only.
5.     
Care Point: Remove the left side only.
6.     
7.     

WARNING!
 
Risk of explosion, poisoning and injury working with fuel!
Fuels are highly flammable and toxic if inhaled. Fuel vapours are explosive, invisible and spread out at floor level. This vapour is poisonous when inhaled and has an anesthetizing effect in high concentrations. Fuel can cause damage to skin. For example, skin is degreased when it comes into contact with gasoline fuel.
Observe the national safety precautions and regulations.
Keep fuel away from fire, open light or ignition sources.
Ensure the work place is adequately ventilated.
Never drain or pour in fuels over assembly pits.
Store drained fuel in a suitable and sealed vessel.
Immediately eliminate any fuel which has flowed out.
Conducting work on a vehicle with open flames (e. g. welding etc.).
Before carrying out this work, remove relevant parts of fuel system and seal open fuel lines with plugs.
 

WARNING!
 
Possible fluid spills from vehicle systems during repairs or maintenance.
Risk of thermal incidents, slip hazards, corrosion of electrical components, failure of electrical or mechanical components or unwanted odours.
Always limit fluid spills and fully clean the spilled fluid after repairs or maintenance.
 

Remove fuel tank
 
Care Point:
Use a suitable container to collect any fuel.

 
1.  
Disconnect the hose (1).
 

2.  
Disconnect the hose (2).
 

3.  
Disengage the canister (3) from the clip.
 

4.  
Disconnect the hoses (4).
 

5.  
Disconnect the electrical connector (5).
 

6.  
Remove the nut (6) (M6) 5 Nm and disconnect ground cable.
 

 
Care Point:
Use a support platform to hold the fuel tank before you do the step that follows.

 
7.  
Remove the bolts (7) (M6x25) 9 Nm and remove the fuel tank retention straps.
 
 
Care Point:
You must have the aid of one more person for the step that follows.

Care Point:
Do not let the pipes and harness catch when you lower the fuel tank.

 
8.  
Lower and remove the fuel tank.
 


Install fuel tank
 
Care Point:
Do not let the pipes and harness catch when you install the fuel tank.

Care Point:
Make sure that the routing of the pipes is correct.

Care Point:
Make sure that the fuel hoses are fully engaged.

 
1.  
Install the components in reverse order. Do not install the floor panel - Engine at this time.
 
2.  
Put fuel into the fuel tank.
 
3.  
Connect the McLaren Diagnostic System (MDS).
 
4.  
Go to Diagnostic toolbox in the Engine Control Unit (ECU).
 
5.  
Go to the Sequences section.
 
6.  
Do the Diagnostic Module Leakage Test (DMLT) procedure.
 
7.  
Set the ignition to on.
 
8.  
Examine the fuel system for leaks.
 
 
Care Point:
Only continue when you are sure that there are no leaks.

 
9.  
Install the floor panel - Engine.
 

   
   
   Note