Removing
Place the vehicle on a two-post lift and apply the parking brake.
For vehicles with a body "station wagon"
Tilt the rear row of seats forward (for 5-seater configuration) or middle row (for 7-seater configuration).
Detach and lift upholstery.
Remove the hatch cover of the electric fuel pump.
Disconnect connector 1, Figure 11-29, rear wiring harness from fuel pump module 2.
Figure 11-29 - Disconnecting the rear wiring harness block from the fuel pump module: 1 - block of the rear wiring harness to the fuel pump module; 2 - electric fuel pump module; 3 - fuel tank
Install the hatch cover of the electric fuel pump.
Start the engine and let it run at idle until it comes to a complete stop to relieve pressure in the fuel system, ensuring that exhaust gases are removed (exhaust coil with fan type SERF/SP f. "SovPlym"). Switch off the ignition.
Disconnect wire terminal "masses" from the battery.
Remove as much fuel from the fuel tank as possible. When pumping out fuel, take measures to prevent its leakage (hand pump, process tank).
Remove the right rear wheel.
Loosen nut 1, Figure 11-30, and disconnect wire 2 "masses" from the body under the arch of the rear right wheel (interchangeable head 10, extension, crank).
Unscrew nut 3 securing fuel filler neck 4 to body.
Figure 11-30 - Disconnecting the fuel tank filler neck: 1 - wire fastening nut "masses"; 2 - wire "masses"; 3 - nut for fastening the filler neck of the fuel tank; 4 - filler neck of the fuel tank
Disconnect the diagnostic oxygen sensor block from the mounting bracket (see above).
Remove holders 1, Figure 11-31, heat shield (flathead screwdriver, Phillips screwdriver).
Figure 11-31 - Removing the fuel tank heat shield: 1 - holder; 2 - heat shield of the fuel tank; 3 - fuel tank
Remove heat shield 2 from fuel tank.
For vehicles with K7M engine
Remove the engine crankcase protection.
Operations for all vehicle configurations
Disconnect the exhaust system from the exhaust manifold and vehicle body.
Move the front part of the exhaust system to the left and secure it to the left front suspension arm.
Unscrew the bolts 1, Figure 11-32, fastening the filler neck 2 of the fuel tank to the body (T20 Torx screwdriver).
Figure 11-32 - Disconnecting the fuel tank filler neck: 1 - bolt; 2 - filler neck of the fuel tank
Press the spring clips 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.
Attention. For van vehicles, prevent fuel ejection when fuel pipe 2 is disconnected because the pressure in the fuel line is maintained.
Figure 11-33 - Disconnecting the pipes from the fuel tank: 1 - fuel vapor recovery tube; 2 - fuel tube; 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 fastening nut; 3 - a bolt of fastening of a fuel tank; 4 - fuel tank
Unscrew two nuts 2 and two bolts 3 of the fuel tank (interchangeable head 13, extension, crank).
For vehicles with a body "van"
Lower the fuel tank 4 and disconnect the wiring harness connector from the fuel pump module. Perform the operation with an assistant.
Operations for all vehicle configurations
Remove fuel tank. Perform the operation with an assistant.
Installation
Raise the fuel tank 4, Figure 11-34, and connect the wiring harness connector to the fuel pump module. Perform the operation with an assistant.
Install fuel tank. Perform the operation with an assistant.
Install nuts 2 and bolts 3 for securing the fuel tank. Tightening torques:
- fuel tank nut 21 Nm (2.1 kgf·m);
- fuel tank bolt 21 Nm (2.1 kgf·m) (interchangeable head 13, extension, knob, torque wrench).
Connect pipes 1 and 2, Figure 11-33, to the fuel tank 3 by moving along the axis of the fitting until the connector spring lock clicks. Check the tubes are secure.
Fasten cables 2, Figure 11-34, of the parking brake in holders on the body and fuel tank.
Install the exhaust system.
Attach the block of the diagnostic oxygen sensor 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, fastening the filler neck 2 of the fuel tank to the body (T20 Torx screwdriver).
Connect wire 2, Figure 11-30, "masses" to the body under the arch of the right rear wheel. Tightening torque for wire nut 1 "masses" to body 8 Nm (0.8 kgf·m) (interchangeable head 10, extension, knob, torque wrench).
Tighten nut 3 securing the filler neck 4 of the fuel tank to the body. The moment of an inhaling of a nut of fastening of a bulk mouth to a body 4 Nm (0.4 kgf·m) (interchangeable head 10, extension, crank).
For vehicles with K7M engine
Install the engine crankcase protection.
Operations for all vehicle configurations
Install the heat shield 2, Figure 11-31, of the fuel tank and secure with holders 1 of the heat shield.
Install the right rear wheel.
Attach wire terminal "masses" to the battery.