Peugeot 405 Manual

Fuel tank - removal and refitting
Fuel/exhaust systems - carburettor models / Fuel tank - removal and refitting

Note: Refer to the warning note in Section 1 before proceeding.

1 Before removing the fuel tank, all fuel must be drained from the tank. Since a fuel tank drain plug is not provided, it is preferable to carry out the removal operation when the tank is nearly empty. Before proceeding, disconnect the battery negative lead and syphon or hand-pump the remaining fuel from the tank.

2 Remove the exhaust system and relevant heat shield(s) as described in Section 16.

3 From underneath the vehicle, disconnect the handbrake cable at the equaliser bracket.

4 Release the handbrake primary cable from the clips in the fuel tank. Position the cable clear of the tank, so that it will not hinder the removal procedure.

5 Disconnect the wiring connector from the fuel gauge sender unit, as described in Section 5.

6 Working at the right-hand side of the fuel tank, release the retaining clips then disconnect the filler neck vent pipe and main filler neck hose from the fuel tank/filler neck.

Where necessary, also disconnect the breather hose(s). Some breather hoses are joined to the tank with quick-release fittings; to disconnect these fittings, slide the cover along the hose then depress the centre ring and pull the hose out of its fitting (see illustration).

6.6 Tank breather quick-release connector
6.6 Tank breather quick-release connector

8 Cover 9 Centre ring 10 Hose

7 Trace the fuel feed and return hoses back from the right-hand side of the tank to their union with the fuel pipes. Slacken the retaining clips and disconnect both hoses from the fuel pipes. Where the crimped-type Peugeot hose clips are fitted, cut the clips and discard them; use standard worm-drive hose clips on refitting. Plug the hose and pipe ends, to prevent the entry of dirt into the system.

8 Place a trolley jack with an interposed block of wood beneath the tank, then raise the jack until it is supporting the weight of the tank.

9 Slacken and remove the retaining nut and bolts, then remove the two support rods from the underside of the tank (see illustration).

6.9 Fuel tank support strap bolt
6.9 Fuel tank support strap bolt

10 Slowly lower the fuel tank out of position, disconnecting any other relevant vent pipes as they become accessible (where necessary), and remove the tank from underneath the car.

11 If the tank is contaminated with sediment or water, remove the sender unit (Section 5), and swill the tank out with clean fuel. The tank is injection-moulded from a synthetic material - if seriously damaged, it should be renewed.

However, in certain cases, it may be possible to have small leaks or minor damage repaired.

Seek the advice of a specialist before attempting to repair the fuel tank.

12 Refitting is the reverse of the removal procedure, noting the following points: a) When lifting the tank back into position, take care to ensure that none of the hoses become trapped between the tank and vehicle body.

b) Ensure that all pipes and hoses are correctly routed, and securely held in position with their retaining clips.

c) Reconnect the handbrake cables and adjust the handbrake (see Chapter 9).

d) On completion, refill the tank with a small amount of fuel, and check for signs of leakage prior to taking the vehicle out on the road.

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