Removal
Place the vehicle on a two-post lift and apply the parking brake.
For vehicles with a "station wagon" body
Tilt the rear row of seats forward (for 5-seater configuration) or the middle row (for 7-seater configuration).
Disconnect and lift the floor trim.
Remove the electric fuel pump hatch cover.
Disconnect connector 1, Figure 11-29, of the rear wiring harness from module 2 of the electric fuel pump.
Figure 11-29 - Disconnecting the rear wiring harness connector from the electric fuel pump module: 1 - rear wiring harness connector to the electric fuel pump module; 2 - electric fuel pump module; 3 - fuel tank
Install the electric fuel pump hatch cover.
Start the engine and let it run at idle speed until it stops completely to relieve pressure in the fuel system, ensuring the exhaust gases are removed (exhaust coil with a fan of the SERF/SP type from SovPlym). Turn off the ignition.
Disconnect the ground wire terminal from the battery.
Remove as much fuel as possible from the fuel tank. When pumping out fuel, take measures to prevent leakage (brush pump, process tank).
Remove the right rear wheel.
Unscrew nut 1, Figure 11-30, and disconnect ground wire 2 from the body under the rear right wheel arch (replacement head 10, extension, ratchet).
Loosen nut 3 securing filler neck 4 of the fuel tank to the body.
Figure 11-30 - Removing the fuel tank filler neck: 1 - nut for fixing the "mass" wire; 2 - "ground" wire; 3 - Fuel tank filler neck fastening nut; 4 - fuel tank filler neck
Disconnect the oxygen sensor diagnostic connector from the mounting bracket (see above).
Remove the holders 1, Figure 11-31, of the heat shield (flat head screwdriver, cross head screwdriver).
Figure 11-31 - Removing the fuel tank heat shield: 1 - holder; 2 - fuel tank heat shield; 3 - fuel tank
Remove the heat shield 2 from the fuel tank.
For cars with K7M engine
Remove the engine crankcase guard.
Operations for all vehicle configurations
Disconnect the exhaust system from the exhaust manifold and the vehicle body.
Move the front part of the exhaust system to the left and secure it to the left arm of the front suspension.
Loosen bolts 1, Figure 11-32, securing filler neck 2 of the fuel tank to the body (screwdriver with Torx T20 bit).
Figure 11-32 - Removing the fuel tank filler neck: 1 - bolt; 2 - fuel tank filler neck
Press the spring clamps of the tube connectors 1 and 2, Figure 11-33, and by moving along the axis of the fittings, disconnect the tubes from the fuel tank 3.
Caution: For van vehicles, prevent fuel from escaping when disconnecting fuel pipe 2, as pressure in the fuel line is maintained.
Figure 11-33 - Disconnecting the pipes from the fuel tank: 1 - fuel vapor recovery tube; 2 - fuel pipe; 3 - fuel tank
Disconnect the parking brake cables 1, Figure 11-34, from the holders on the body and fuel tank.
Figure 11-34 - Removing the fuel tank: 1 - parking brake cable; 2 - fuel tank mounting nut; 3 - fuel tank mounting bolt; 4 - fuel tank
Unscrew two nuts 2 and two bolts 3 securing the fuel tank (replacement head 13, extension, ratchet).
For vehicles with a "van" body
Lower the fuel tank 4 and disconnect the wiring harness connector from the electric fuel pump module. The operation must be performed with an assistant.
Operations for all vehicle configurations
Remove the fuel tank. The operation must be performed with an assistant.
Installation
Raise the fuel tank 4, Figure 11-34, and connect the wiring harness connector to the electric fuel pump module. The operation must be performed with an assistant.
Install the fuel tank. The operation must be performed with an assistant.
Install nuts 2 and bolts 3 for securing the fuel tank. Tightening torques:
- fuel tank mounting nut 21 N·m (2.1 kgf·m);
- fuel tank mounting bolt 21 N·m (2.1 kgf·m) (replaceable head 13, extension, ratchet, torque wrench).
Connect tubes 1 and 2, Figure 11-33, to fuel tank 3 by moving along the axis of the fitting until the spring lock of the connector clicks. Check the reliability of the tubes.
Secure the parking brake cables 2, Figure 11-34, to the holders on the body and fuel tank.
Install the exhaust system.
Attach the oxygen sensor diagnostic connector to the mounting bracket (see above).
Connect the wiring harness connector to the diagnostic oxygen sensor connector (see above).
Install bolts 1, Figure 11-32, securing the fuel tank filler neck 2 to the body (screwdriver with Torx T20 bit).
Connect wire 2, Figure 11-30, "ground" to the body under the arch of the right rear wheel. Tightening torque of nut 1 for fastening the ground wire to the body 8 N·m (0.8 kgf·m) (replaceable head 10, extension, ratchet, torque wrench).
Tighten nut 3 securing filler neck 4 of the fuel tank to the body. Tightening torque of the nut securing the filler neck to the body 4 Nm (0.4 kgf·m) (replacement head 10, extension, ratchet).
For cars with K7M engine
Install the engine crankcase guard.
Operations for all vehicle configurations
Install heat shield 2, Figure 11-31, of the fuel tank and secure with heat shield holders 1.
Install the right rear wheel.
Connect the ground wire terminal to the battery.