Peugeot 308: Removing - refitting : Fuel tank

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

1. Tooling

Tool	Reference	Description
	[1617-J]	HDI plugs kit
	[0004-Z][WE-160002-A]	Lifting table

2. Preliminary operations

Place the vehicle on a 2-post lift.

CAUTION : Perform the operations that are required before disconnecting the ancillaries batteries .

Disconnect the ancillaries batteries (Following the specific procedure).

Drain the fuel tank .

Remove (depending on equipment) :

• The rear wheels
• The rear right-hand mud guard
• The protectors under the body
• The under-engine protector
• The rear suspension
• The exhaust line (Do not cut the exhaust rear silencer )
• The exhaust heat shields

3. Removing

Uncouple the fuel vapour pipes (2) (at "a").

Remove the bolt (1).

Disconnect the fuel vapour leak measuring device connector (at "b").

Unclip the electrical harness (3) (at "c").

Unclip the electrical harness (3) (at "d").

CAUTION : Do not open the traction battery cooling circuit .

Uncouple the traction battery cooling circuit pipes (4) (at "e").

Remove the nut (5).

Move aside the traction battery cooling circuit pipes (4) (In the direction of the arrow ).

Uncouple the fuel vapours recirculation pipe (6) (at "g").

Detach and move aside the fuel pipe (7) (at "f").

Support the fuel tank (8) ; Using the lifting table [0004-Z] / [WE-160002-A].

Remove :

• The nuts (10), (11)
• The 2 bolts (9)

Lower the fuel tank (8) by 30 cm ; Using the lifting table [0004-Z] / [WE-160002-A].

CAUTION : Guide the fuel tank (8) filler neck to avoid stress in the surrounding area.

Move the traction battery cooling circuit pipes (4) away from the fuel tank (8) (at "h").

Move the traction battery cooling circuit pipes (4) away from the fuel tank (8) (at "j").

Unclip the electrical harness (3) (at "k").

CAUTION : Before uncoupling, clean the fuel pipe (7) (at "p").

CAUTION : Plug the fuel pipe (7)) (at "p") ; Using the tool [1617-J].

Disconnect the electrical harness (13) connector (at "n").

Uncouple the fuel pipe (7) (at "p").

Disconnect the electrical harness (12) connector (at "l").

Unclip the electrical harness (12) (at "m").

Remove the fuel tank (8).

4. Refitting

CAUTION : Observe the tightening torques.

PHEV DRIVE TRAIN

Tightening torques :

• Exhaust line
• Components of the fuel circuit
• Wheels

CAUTION : Remove the plugs [1617-J] (at "p").

Position the fuel tank (8) 30 cm from its position under the vehicle ; Using the lifting table [0004-Z] / [WE-160002-A].

Reconnect the electrical harness connector (12) (at "l").

Couple up the fuel pipe (7) (at "p").

Reconnect the electrical harness connector (13) (at "n").

Clip the electrical harness (12) (at "m").

Refit the traction battery cooling circuit pipes (4) (at "j").

Clip the electrical harness (3) (at "k").

Refit :

• The traction battery cooling circuit pipes (4) (at "h")
• The fuel tank (8)
• The nuts (10), (11)
• The 2 bolts (9)

Move aside the lifting table [0004-Z] / [WE-160002-A].

Reclip the fuel pipe (7) (at "f").

Couple the fuel vapours recirculation pipe (6) (at "g").

Refit the nut (5).

Couple the traction battery cooling circuit pipes (4) (at "e").

Clip :

• The electrical harness (3) (at "d")
• The electrical harness (3) (at "c")

Reconnect the fuel vapour leak measuring device connector (at "b").

Refit the bolt (1).

Couple up the fuel vapour pipes (2) (at "a").

5. Additional operations

Refit (depending on equipment) :

• The exhaust heat shields
• The exhaust line
• The rear suspension
• The under-engine protector
• The protectors under the body
• The rear right-hand mud guard
• The rear wheels

Fill the fuel tank (8) .

Return the vehicle to its wheels.

CAUTION : Perform the operations that are required after reconnecting the ancillaries batteries .

Reconnect the ancillaries batteries (Following the specific procedure).

Prime the fuel circuit (Switch the ignition on and off 2 times).

Start the engine.

Check :

• That there are no leaks
• The operation of the fuel gauge

Switch off the engine.