Table of contents: Removal ↓ Installation ↓
Note: Before starting work, read the warnings contained in paragraph 1.
Removal
1. Before removing the tank, it is advisable to drain the maximum possible amount of fuel from it. Since there is no drain plug, it is preferable to remove the tank when there is a minimum of fuel left in it. You can drain the fuel using the siphon method into a canister.
2. Disconnect the ground cable from the battery as described in chapter 5A.
3. As described in chapter 11, remove the decorative floor trim in the luggage compartment.
4. Loosen the screws securing the hatch and remove it from the floor.
5. Disconnect the wiring connector from the pump/sensor assembly. Do not disconnect the fuel hoses.
6. Open the filler door and wipe the area around it. Using a screwdriver, gently pry off the rubber cup ring around the filler neck.
7. Remove the rubber cup from the opening in the body.
8. Place chocks under the front wheels, jack up the rear of the car and install safety supports. Remove the right rear wheel.
9. Remove the right rear mudguard.
10. Unscrew the bolt securing the filler neck and protective plate to the body. The bolt also secures the ground wire.
11. If equipped, remove the lower skid plate in front of the rear beam.
12. In front of the tank, attach identification tags to the fuel lines and the evaporative hose of the canister under the bottom. Loosen the clamps and disconnect the hoses. Place a container under the hoses to collect the fuel.
13. Support the tank with a trolley jack, placing a piece of board between them.
14. Mark the position of the tank mounting straps to reinstall them correctly and remove them. Note the position of the ground wire on the rear mount.
15. Together with an assistant, lower the tank down and remove it from under the car.
16. If the tank is dirty inside or there is water in it, remove the sensor/pump assembly as described in paragraph 4 and flush the back with clean fuel. The tank is made of plastic; the damaged tank is replaced. However, in some cases minor leaks can be repaired - seek advice from a specialist.
Installation
17. Installation is the reverse of the procedure. Please note the following:
- a) Make sure that the hoses and wiring are not pinched during reinstallation.
- b) Properly route and secure all hoses and tubes.
- c) Before tightening the tank mounting strap bolts, push the tank to the right until it stops.
- d) It is very important to correctly secure the ground wire to the strap and filler neck. Connect an ohmmeter between the metal ring of the filler neck and the open metal part of the body - the ohmmeter should show zero.
- d) Finally, fill the tank with fuel before driving on the road and check for any signs of leaks.
- e) Connect the battery - see chapter 5.
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