Basically, If you burn your face off it's not my fault.
You will need
E12 Torx bit
2 x 13mm Spanners
2 x 17mm spanners
2 x Trolley jack
1 x Scissor jack
Small posi screwdriver
Big flat head screwdriver
Start by removing both rear under trays and putting them out of the way. Then Jack up the entire car corner by corner and put bricks under each wheel. I went for three layers of bricks with three bricks per layer and a thin piece of wood on the top of each to protect the tyres. Chock both front wheels (in front and behind) to stop the car from moving around. Put the car in gear and take the hand brake off.
When you get to this point open the engine bay lid and remove the gear cable locator bolt and make sure you don't lose the bushes that dampen the cables from the gearbox.
Now use a big flat head screw driver to lever off the gear cable ends from the selector being careful not to knock it out of gear (if you do you can re-engage it by hand)
Get underneath the car and you will see a hook which guides the cables through the engine bay. Use a 10mm spanner to undo where it is bolted onto the block.
Right underneath the shear panel the cables are fastened to the car by two bolts, undo these and place to one side. If you have the Cornering Force roll bars like me you will need to unbolt the part where it attaches to the DS wishbone to feed the gear cables through.
The TIS says you should detach the handbrake cables from the calipers but I took a different route for this. start by removing the R clip from the handbrake compensator. Then push the pin it was securing through the assembly towards the shear panel. This will detach the two parts from each other.
Next remove the shear panel by taking the five 13mm bolts out closest to the passenger compartment, the four 17mm nut and bolts that pin the wishbone mounts to the panel (you will need to use two 17mm spanners for this), the two 10mm that connect the engine mount and the two 13mm nut and bolts in the rear corners. From here the panel can be removed and placed out of the way.
This next step is not vital but I would highly recommend it as I learnt the hard way. When you get to this point go inside the car and remove the passenger side seat (four Allen head bolts connecting to the chassis and a 17mm bolt for the seat belt) and take out the rear parcel shelf thing (6 plastic screws and rivets and two 17mm seat belt bolts). When it is out you will see a small inspection hatch on the passenger side. I will come back to this later.
Put two jacks under the tank (one per side) and remove the 4 13mm bolts that connect it to the chassis.
Start lowering it down gently and evenly until the drivers side won't go any further. It will be stopped by the hoses going to the evaporation canister and the fuel filler neck.
Next loosen the DS rear wheel nuts and jack up the back of the car by the lowest subframe point (where the big bolts of the rear under tray connect). Place an axel stand under the point directly below the engine mount (taking care not to obstruct the tanks removal path) and remove the rear wheel. Take out the arch liner and you should be able to see the evaporation tank up near the filler neck spout.
There are three hoses that lead from the tank to this unit which are secured by some crushed on clips. I couldn't find an easy way to remove these so I cut them off with a pair of snips. once the clips are removed pull off the pipes and cover their tops with some gaffa tape to reduce petrol fumes. Next remove the two Jubilee
clips where the filler neck joins the tank feed pipe and pull these two apart. Cover this pipe top with gaffa tape too.
You should now be able to lower the tank down further but the kink in the fuel feed pipe and bottom clips mean a bit of persuasion is required. When the tank is about half out go back to the engine bay and release the pressure from the fuel rail by unscrewing the plastic cover and depressing the valve with a rag (A small amount of fuel will come out). Next go into the car and remove the inspection hatch. Through it you will see fuel feed, return and pump power connectors going into the fuel pump. Unclip the power multi-plug, place a rag under the fuel connectors and remove the fuel lines by pressing the side buttons in and pulling it away from the pump. A small amount of fuel will come out during this process. Dry up the connectors and put some tape on the ends.
Edited by SteveA, 11 October 2012 - 02:32 PM.