Fuel tank replacement

If a fuel leak is detected from the tank, it is recommended to replace the tank. If the fuel pump screen is often clogged, remove and flush the tank.

Note. It is more convenient to remove an empty fuel tank while working on a lift, overpass or viewing canvas. Before removing the fuel tank, try to run out most of the fuel or pump it out through the fuel filler neck with a hose.

You will need: socket wrench «at 13», TORX T30 wrench, flat blade screwdriver.

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

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

3. Remove the heat shield (see «Removal and installation of thermal screens»).



4. Loosen the clamp that secures the connecting hose to the fuel filler pipe..



5.... slide the clamp along the hose..




6.... and disconnect the hose from the fuel filler pipe.



7. Prying with a screwdriver, unclench the clamp that secures the connecting hose to the ventilation pipe branch pipe..



8.... move the clamp..



9.... and disconnect the hose from the nozzle.

Note. The ventilation hose clamp is disposable, replace it with a new one when assembling.

10. Install supports under the fuel tank..



11.... unscrew the two bolts securing the clamps to the base of the body at the rear..



12.... and one bolt in front.

13. Lower the fuel tank.




14. In the opening that appears between the fuel tank and the base of the body, disconnect the wiring harness block, high pressure fuel lines and drain line from the fuel pump module.



15. Disconnect the tip of the outlet line from the adsorber fitting..



16.... and remove the fuel tank.


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

18. Fill the tank with fuel, start the engine and check the tightness of all fuel line connections.

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

1. Remove the left rear wheel (see «Wheel replacement»).

2. Remove the left mudguard (see «Removal and installation of wheel mudguards and fender liner»).

3. Disconnect the filler pipe and the ventilation pipe from the connecting hoses of the fuel tank (see paragraphs. 4-9 of this subsection).



4. Turn out one screw of the bottom fastening of a filling pipe..



5. …one side mount screw…



6.... and remove the fuel tank filler pipe assembly with the ventilation pipe.

7. Install parts in reverse order.