Precautionary measures
Do not use open fire, do not smoke, and do not bring hot or very hot objects to the workplace - this is a fire hazard! Prepare a fire extinguisher.
Ensure good ventilation of the workplace - fuel vapors are toxic.
The fuel system is under pressure. When opening the system, gasoline may spray out, which should be collected with a rag. Wear protective glasses when working.
Note: A special pump is required to suck out the fuel. A jack and four stands are required to support the vehicle.
Removal
Drive a car until all the gas in the tank is used up.
Disconnect the negative cable from the battery with the ignition off. This will erase the data from the electronic memory units, such as radio codes. See the instructions in the chapter "Electrical equipment".
Unscrew the fuel tank cap and suck out the remaining fuel from the tank using a pump, following the operating instructions.
Raise and support the vehicle.
Unhook the exhaust system from the rubber mounts at the front and rear, lower it slightly and hang it on a wire under the bottom of the car body.
Unscrew and remove the middle and rear heat shields of the exhaust system.
Ford Fiesta/Mazda 121: unscrew the bolts and remove the heat shield of the tank.
Loosen the hose clamp and pull the ventilation hose off the tank.
Support the vehicle from behind and support the fuel tank with a jack, placing a block of wood under its head to avoid damaging the surface of the tank.
Precautions: The gasoline injection system is under pressure. When opening the system, fuel may spray out, which should be collected with a rag. Wear goggles when working.
Gasoline engine: Place a container underneath to catch the drain. Pull the fuel outlet line off the quick release coupling on the fuel filter.
Unscrew the bolts and carefully lower the fuel side down a little.
Caution: The filler neck remains on the vehicle. Unhook the tank from the filler neck.
Remove the fuel quantity sensor/fuel pump plug.
Pull the return fuel line off the top of the tank by squeezing the quick release coupling. On a diesel engine, remove the two fuel lines. To make installation easier, it is best to mark the connecting nipples and fuel lines with strips of adhesive tape.
Pull off the ventilation pipe from the safety valve. Remove the safety valve from the holder.
Check that all wires, tubes and hoses are disconnected. Remove the fuel tank.
Installation
Before installation, check the fuel tank for damage and replace it if necessary.
Lubricate the gasket on the filler neck of the tank with clean engine oil to make it easier to fit the neck.
Place the fuel tank in the installation position and install the fuel sensor/fuel pump plug.
Insert the safety relief valve into the holder and put on the ventilation hose.
Put on the upper fuel line (fuel lines) on quick-release connections.
Install the fuel tank and secure it with bolts.
Gasoline engine: Attach the fuel hose connection to the fuel filter.
Place the ventilation pipe on top of the fuel tank and secure it with a clamp.
Install the heat shield on the underbody of the vehicle.
Hang the exhaust system on rubber hangers, remove the wire on which it was hanging previously.
Lower the car.
Fill the tank with fuel and tighten the tank cap.
Connect the negative cable to the battery. Set the clock and enter the required radio codes.
Start the engine and check the operation of the fuel gauge on the instrument panel.