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Autopapyrus · Chery Fora (1st generation, A21)
https://autopapyrus.com/guides/chery/fora/fuel-tank-and-filler-neck-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Chery Fora (1st generation, A21): Fuel Tank and Filler Neck Replacement

The Chery Fora fuel tank is located under the body floor behind the rear seat and is held by two metal retaining straps. The filler neck runs to the right rear fender and is connected to the tank by a hose. The exact procedure for this model is not documented in open service materials, so this is a general procedure. Check tightening torque values against the manufacturer's specifications.

Difficulty: Hard Time: 3-5 hours Steps: 13 Tools: Lift or inspection pit, transmission jack or a helper, sockets and wrenches (approximately 10-17 mm), fuel quick-disconnect line tool set, flat screwdriver, plastic trim clip tools, container for draining fuel, hose and hand pump for siphoning, CO2 fire extinguisher, new clamps and clips

Part

  • 🔩 Fuel tank assembly, filler neck (pipe) assembly, fuel pump module sealing ring, and, if worn, clamps and the hose between the filler neck and the tank, fuel filler cap. Catalog numbers for this model are not confirmed in open sources, so no part number is given

Step by step

13 steps
  1. Work outdoors or in a well-ventilated area, away from open flames. Disconnect the negative battery terminal. Run the fuel level down as low as possible beforehand: the less gasoline in the tank, the safer and easier it is to remove.
  2. Relieve the pressure in the fuel system. Remove the fuel pump relay or fuse, start the engine and wait until it stalls, then crank the starter for 2-3 seconds. Put the relay back only during reassembly.
  3. Raise the rear of the vehicle on a lift or jack stands. Do not work under a vehicle supported only by a jack.
  4. Remove the rear seat (cushion) and open the fuel pump module access cover in the floor. Disconnect the electrical connector of the pump and the fuel level sender. Then disconnect the fuel lines at the quick-disconnect fittings, placing a container and a rag underneath.
  5. Drain the remaining gasoline from the tank. If there is no drain plug, siphon the fuel out through the filler neck or through the pump module opening with a hand pump. Store the gasoline in an approved fuel container.
  6. Remove the underbody shield, if fitted, and inspect the area next to the tank: the exhaust pipe and heat shield, parking brake rods or cable may be in the way. If they interfere, detach or lower them without damaging the suspension.
  7. To replace the filler neck, open the fuel filler door. Unbolt the filler neck from the body and remove the rear right wheel arch liner to reach the neck. Loosen the clamps on the hose between the filler neck and the tank, and remove the vapor recovery (vent) hose if it is connected.
  8. Support the tank with a jack through a wooden block, or have a helper hold it. Remove the bolts of the two retaining straps and carefully lower the tank. Check the vent hoses and valves as well as the wiring before lowering the tank all the way.
  9. Remove the filler neck assembly downward or toward the inside of the wheel arch, depending on the configuration. If you are replacing only the filler neck, you do not need to remove the tank completely; just lower it slightly to free the hose.
  10. Transfer the fuel pump module to the new tank: replace the sealing ring, and check the pump strainer and the condition of the filter. Do not use silicone grease. Lubricate the seal with clean gasoline or a special fuel-system lubricant.
  11. Install the new tank and filler neck in reverse order. Make sure the straps sit in their original positions, the pads and rubber gaskets are in place, and the hoses are not twisted and do not touch the exhaust. Tighten the straps and clamps to the manufacturer's specifications.
  12. Reconnect the lines and connectors, and make sure the quick-disconnect fittings have clicked into place (pull on them by hand). Install the pump relay and connect the battery. Turn the ignition on and off several times without starting the engine to build up pressure.
  13. Add 5-10 L (1.3-2.6 gal) of gasoline. Check all connections for leaks with the ignition on and after the engine has started. Install the seat, the wheel arch liner and the underbody shield.

Common mistakes and warnings

  • Gasoline and its vapors are explosive: no open flames, sparks or smoking, and keep a fire extinguisher nearby. Do not store or move a tank containing residual fuel in enclosed spaces. If you suspect a defect in the filler neck, hose or fuel lines and have no experience working on fuel systems, it is better to leave the job to a repair shop, since a leaking connection creates a fire risk.