Warnings: The fuel tank is removed from the bottom of the vehicle. Use a jack to support the fuel tank.
Even in an empty fuel tank, there are fuel vapors that are explosive, so be careful.
Pic. 4.1–3. Fuel tank: 1 - bolt, 23 Nm; 2 - diagonal transverse tape; 3 - fuel supply pipe; 4 - hollow bolt, 23 Nm; 5 - gaskets; 6 - fuel return pipe; 7 - fuel supply pipe; 8 - double hose clamp, 9 - lower hose connection; 10 – fuel tank; 11 - transverse beam; 12 - bolt, 23 Nm; 13, 14 - tapes for fixing the fuel tank
When installing the fuel tank, pay attention to the different length of the tapes (pic. 4.1–3).
Before disconnecting the battery, find out if you have a radio activation code.
Turn off the ignition and disconnect the wire ««masses»» from the battery.
Drain the fuel from the fuel tank.
Remove the fuel gauge/fuel pump covers located on the left and right sides under the trunk carpet.
Disconnect the electrical connectors from the fuel level sensor/fuel pump and move them to the side.
Remove rear wheels.
Unscrew the four bolts securing the cross member located under the mufflers.
Unscrew nuts of fastening of couplings of connection of pipes of system of release and disconnect rear section of system of release.
Remove the two thermal protection panels from both sides of the rear axle.
From the bottom of the vehicle, unscrew the fuel tank covers on both sides of the vehicle.
Disconnect the parking brake cable clamps and move the cable to the side.
Front wheel drive vehicles
Using a spring compressor, compress the rear suspension springs one by one and remove them.
Place a jack with base plate under the rear frame and support the frame with the jack.
Pic. 4.1–4. Installation of the jack and the location of the bolts of the lower rear frame
Unscrew the four bolts securing the lower rear frame (pic. 4.1–4).
If the fuel tank is removed for a long time, after removing it, fix the lower frame with bolts.
4x4 vehicles
Remove the rear axle.
All models
Loosen the bottom hose double clamp between the fuel tank and the fuel feed pipe, leaving the bottom hose on the fuel tank.
Pic. 4.1–5. Location of the fuel tank pipes: 1 - clamps for fastening the tube connecting the expansion chamber with the fuel supply pipe; 2 - fuel supply pipe
Loosen clamps 1 (pic. 4.1–5) and disconnect the tube connecting the expansion chamber to the fuel supply pipe, while the connecting tube must remain on the supply pipe.
Label the rest of the fuel tank pipes and disconnect them.
Pic. 4.1–6. Location of feed tubes (1) and return (2) fuel near the fuel filter
Disconnect tube 1 (pic. 4.1–6) from the fuel filter.
Disconnect the fuel return pipe 2.
Disconnect the electrical connectors on the left and right side of the fuel tank mounting cross member bracket.
Unscrew nuts and remove a cross beam.
Pic. 4.1–7. An arrangement of tapes of fastening of a fuel tank: 1, 2 – forward tapes; 3 - diagonal tape; 4, 5 - rear tapes for fixing the fuel tank
Unscrew the front tapes 1 and 2 fastening the fuel tank (pic. 4.1–7).
Place a jack with support plate under the right section of the fuel tank and raise the jack just enough to support the weight of the fuel tank on the jack.
Unscrew the rear tapes 4 and 5 fastening the fuel tank (pic. 4.1–7).
With a second person, lower the fuel tank, being careful not to bend the fuel lines.
Unscrew the diagonal tape.
Installation
Installation is carried out in the reverse order of removal.
Make sure that parking brake cables correctly positioned and secured with clips.
Pic. 4.1–8. The location of the fuel pipes before installing the fuel tank: 1 - fuel pipes going to the fuel tank; 2 – flexible mounting element; 3 - filler neck
Check that the fuel pipes leading to the fuel tank through the hole in the body are located as shown in Figure 4.1–8.
Connect wire «masses» to the battery.
Start the engine and check the tightness of the power system.
Turn on radio and enter the code into it.
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