Fuel tank 1. Fuel filler cap; 2. Rubber bushing; 3. Filler pipe; 4. Cover; 5. Clamp; 6. Filler hose; 7. Clamp; 8. Fuel tank protection; 9. Fuel tank band clamp (left); 10. Fuel tank band clamp (right); 11. Fuel tank; 12. Clamp; 13. Ventilation hose.
Removal and installation
Removal
1. Follow steps 2 7 steps. «Removal» («Fuel level sensor, fuel filter and fuel pump assembly») higher.
2. If necessary, drain the fuel from the fuel tank. See above.
Attention:
- Since the fuel tank tilts forward and becomes unstable during removal/installation, the remaining fuel must be drained.
- Stop the vehicle on a level and firm surface.
3. Remove the main muffler. See below.
4. Remove the driveshaft. See chapter «Power transmission (on 4WD models)».
5. Remove the fuel tank protection.
6. Disconnect the ventilation hose (1) on the back of the fuel tank.
7. Disconnecting the EVAP tube (2) on the back of the fuel tank.
- Instructions for separating the quick connector (A) EVAP tubes see above.
8. Disconnect the filler hose (3) from the side of the filler pipe.
9. Remove the suspension bar. See chapter «Rear axle and suspension (on 4WD models)».
10. Unscrew the parking brake cable mounting bolts and separate the cable from the suspension arm. See chapter «Brake system (on 4WD models)».
11. Disconnect the connector from the 4WD solenoid valve (on 4WD models).
12. Loosen the fastening nut (A) main gear on the rear suspension beam (1). See chapter «Rear axle and suspension (on 4WD models)».
Attention. Do not unscrew the final drive mounting nut.
13. Remove the mounting bolts (IN) final drive from mounting bracket (3) final drive and tilt final drive assembly (2). See chapter «Power transmission (on 4WD models)».
Note. It is not necessary to remove the final drive assembly from the vehicle.
14. Support the central part of the fuel tank (1) telescopic stand (A).
Attention. Lay a wooden block (IN) between the telescopic stand and the fuel tank.
15. Remove the fuel tank strap clamps on the right and left.
16. While supporting the fuel tank with your hands, carefully lower the telescopic stand and remove the tank.
Attention. The fuel tank may be in an unstable position due to the shape of its bottom. Do not rely on the telescopic stand. Support the tank securely with your hands.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
Filler hose.
- Place the hose onto the tube to a depth of 35 mm and secure with a clamp.
- Make sure the hose clamp is not stuck on the thick part (shoulder) fuel pipe.
- Tighten the fuel hose clamp so that the distance from the end of the hose is:
Filler pipe side: 7-11 mm
Fuel tank side: 5-9 mm
EVAP hose
1. Check for damage to the joints and for foreign particles.
2 Center the fitting with the hose, then insert the fitting at a right angle until it clicks.
3. After connecting, make sure the connection is secure by pulling the quick release fitting with your hand and (central fuel line under the bottom)
A. Pull
Check after installation
Check for fuel leaks as follows:
1. Turn the ignition key to position «ON» (without starting the engine). After creating pressure in the fuel lines, check for fuel leaks at the joints.
2. Start the engine. While increasing the engine speed, check again for fuel leaks at the joints of the fuel lines and hoses.