Replacing the fuel tank and its filler pipe

If a fuel leak is found in the tank, replace the tank, as it is molded from special plastic and cannot be repaired.

If the fuel pump screen is often clogged, remove and flush the tank.

USEFUL ADVICE: It is more convenient to remove an empty tank while working on a lift, overpass or inspection ditch. For removing fuel residues after disconnecting the connecting hose of the filling pipe from the tank nozzle (see paragraphs below. 7 and 8) pump out the fuel through the opened hole in the tank.

You will need: keys «on 10», TORX T20 and T30 socket «at 13», pliers with thin jaws, a screwdriver with a flat blade.

1. Reduce the pressure in the supply system (cm. «Reducing the pressure in the power system»).

2. Disconnect the wire from the terminal «minus» battery.



3. Disconnect the injection and drain hoses of the fuel pump from the pipelines..



4.... by squeezing their latches.




5. Disconnect the pipes from the canister of the evaporative emission system..



6.... by squeezing their latches.



7. Loosen the clamp fastening the connecting hose of the filler pipe to the fuel tank nozzle..



8.... and disconnect the hose from the nozzle, at the same time removing the clamp from the hose so as not to lose it.




9. Turn off two nuts of fastening of the thermoscreen of the main muffler to a collar of fastening of a fuel tank..



10.... and carefully bend the edge of the thermal screen down, removing it from the clamp studs.



11. Remove the two screws securing the protective shield to the side member..




12.... and remove the shield.



13. Place a secure support under the tank.



14. Turn out one bolt of fastening of a collar of a fuel tank to the basis of a body in its forward part …



15.... two bolts in the back..




16.... and lower the tank down a little so that access to its upper surface opens.



17. Disconnect the wiring harness block from the fuel pump module by squeezing its clips.



18. Put another tank down..



19.... loosen the clamp fastening to the tank fitting of the air outlet pipe of the filling pipe, slide the clamp along the hose..



20.... disconnect the hose from the fitting, remove the support and remove the fuel tank.

21. Install the fuel tank in the reverse order of removal.

22. After connecting the pipelines and the fuel pump wiring harness, fill the tank with gasoline, start the engine and check the tightness of all pipeline connections.

If needed remove the fuel filler pipe, do the following.

1. Remove the right rear wheel and place the vehicle on a secure stand.

2. Remove the right rear fender liner (cm. «Removal and installation of wheel mudguards and fender liner»).



3. Turn out screws of fastening of a bulk pipe of a fuel tank to a sidewall of a body …



4.... and to the right rear side member.



5. Remove the air outlet tube from the holder on the filling pipe.



6. Loosen the clamp that secures the connecting hose of the filler pipe to the fuel tank nozzle..



7.... and disconnect the hose from the nozzle, at the same time removing the clamp from the hose so as not to lose it.



8. Take the filling pipe aside and remove the pipe neck from the seal of its manhole cover.

9. Remove the rear suspension cross member (cm. «Removal and installation of a cross-beam of a back suspension bracket») and remove the fill pipe.

NOTE: Removal of the rear suspension cross member is necessary because the filler pipe cannot be passed through the gap between the cross member and the body when the cross member is installed.

10. Install the parts in the reverse order of removal.