Contents: Removal ⬇ Installation ⬇
Note: Before starting work, refer to the precautions in Chapter 1.
Removal
1. Before removing the fuel tank, drain as much fuel as possible from it.
2. Disconnect the negative battery cable. Use a hand pump to suck out any remaining fuel from the tank.
3. Provide access to the top of the fuel lift pump/sensor as described in Chapter 7, and disconnect the wiring from the sensor/pump,
4. Disconnect the fuel hoses from the pump/sensor. Mark their location to avoid confusion during installation. Working from below, loosen the worm clamp screws and disconnect the filler neck pipe.
5. Loosen the right rear wheel bolts, then jack up the rear of the vehicle and remove the wheel.
6. Loosen the clamps, release the handbrake cables and move them to the side.
7. Place the jack under the center of the tank. Insert a block between the jack head and the tank to prevent damage. Raise the tank slightly.
8. Loosen and remove the tank tie strap mounting bolts.
9. Lower the jack and remove the tank from under the vehicle.
10. If the tank is contaminated with sediment or water, remove the sensor/fuel lift pump assembly (see Chapter 7) and flush the tank with clean fuel. The tank is made of synthetic material and should be replaced if damaged. However, in some cases, minor leaks or minor damage can be repaired. Consult a specialist for advice.
Installation
11. Installation is carried out in the reverse order of removal, paying attention to the following:
- a) When lifting the tank back to its original position, ensure that the rubber cushions are installed in their original position and that none of the hoses are pinched between the vehicle body and the tank.
- b) Ensure that all pipes and hoses are correctly routed, not kinked, and securely fixed in the working position with fastening brackets.
- c) Tighten the mounting bolts to the specified tightening torque Specifications.
- d) Finally, fill the tank with fuel. Check carefully to make sure there are no leaks.