Disassembly – Part 6

Fuel System

Ever wondered what lurked under the battery tray? Well I think it’s a swirl pot – the small reservoir that ensures a steady flow of fuel into the high pressure side of the fuel system. As this sits below the petrol tank, then this was where I started the disassembly to make sure the tank was drained.

Removing the petrol tank itself, requires other stuff to be removed first. Obviously, the feeding and return pipes all need disconnecting, including the filler neck, but you also need to remove the steel strips either side of the boot opening, the right hand of which is the mounting point for the relays and fuel injection electronics.

Once all of that is out of the way the petrol tank slides out. The underside of the petrol tank is susceptible to rust if the rear window has leaked water onto it for long enough. The sound insulation it sits on absorbs the water and keeps the base of the petrol tank moist – nice. In my case, there is some surface rust but nothing more.

Rear Window

As you may have guessed, the rear window has been leaking and needs to be removed so that I can repair the window channels and get access to the corners of the buttresses to repair them too. Removal was not as worrying a job as I had thought. A sharp knife following the line of the chrome trim releases the seal and the rear window comes free. Sounds simple, but there’s a lot of careful cutting, and scraping involved to make sure it comes out in one piece.

So apart from the wiring loom, that’s the boot emptied and ready for the real work to begin.

Disassembly – Part 5

Passengers Door

Having already removed the drivers door I assumed that the same procedure would be required – I was almost right. My small garage ddidn’t allow the passenger door to open completely so the simply practice of removing the screws holding the door car crome plate was impossible with any of my standard screwdrivers. So I had to adapt and create my own tool.

Other than that it came off without too much effort. I am a little concerned as to how it’s going to go back on. The wiring for the remote locking is in such a tricky place behid the window.

The dorr card is is fairly good condition when compared to the drivers side. Don’t think I will need to replace the card itself on this side.

Passengers Seat

No problems here. The screws holding the seat rails came straight out. The seat however has seen better days.