Removal and Replacement

Removing And Installing Fuel Tank

CAUTION:
After installation of fuel tank/prior to first engine start-up:
Check electrical resistance between grounding lead (fuel tank filler pipe) and wheel hub.
Measured value: approx. 0.6 Ohm
Fill fuel tank with at least 5 liters of fuel.







Draw off fuel from fuel tank.
With special tool 34 1 030, unfasten lock nut. Screw down lock nuts and adjusting nuts completely from handbrake cables.

Installation:
Adjust handbrake.







Remove rear seat bench.







Remove rubber plugs (1).







Fold back rubber mat (1).
Release screws (2) and (3).

CAUTION: Do not damage gasket.

Fold back metal covers.







Left fuel tank half:
Disconnect plug connection (1) on fuel level sensor.







Right fuel tank half:
Disconnect plug connection (1) on delivery unit.
Release hose clamp (2), detach fuel tank vent line.

Installation:
Replace hose clamp.
Tightening Torque
7AZ Hose clamps 10 - 16 mm dia. 2 Nm

Remove propeller shaft completely. Removal and Replacement

Removing fuel tank underbody protection on left:







Release metal screws (1).
Unfasten screws (2).







Release screws (1) on wheel arch trim on left.







Bend open wheel arch trim.
Release screw (1).







Release screws (1).







Remove screws (1 and 2).
Unscrew nuts (3).
Remove fuel tank underbody protection on left towards bottom.

Removing fuel tank underbody protection on right:







Release metal screws (1).
Unfasten screws (2).







Release screws (1) on wheel arch trim on right.







Bend open wheel arch trim.
Release screw (1).







Release screws (1).







Release screws (1).
Remove fuel tank underbody protection on right towards bottom.







Unclip handbrake cables (1) and remove from guide tubes.







Remove fuel filter (1).

NOTE:
If necessary, only fuel feed and return lines can also be disconnected from fuel filter.
Release screws, open clamps (2) and detach fuel filter from fuel tank.







NOTE: Unlock connection on carbon canister with special tool 16 1 050.







Detach connection (1) (filling vent).







Remove rear right wheel.
Remove rear right wheel arch trim.







Release hose clamp (1) and detach hose (2) from fuel tank (3).

Installation:
Replace hose clamp.
Tightening Torque
9AZ Hose clamps 37 - 43 mm dia. 4 Nm







Mark following lines before and after separation point (adhesive tape).
(1) Overflow dia. 8 mm
(2) Fuel tank vent dia. 8 mm
(3) Overflow dia. 8 mm
(4) Tank vent dia. 18 mm
(5) Filling vent dia. 18 mm







Open hose clamps so that no hose clamp has to be pulled through wheel arch aperture.

Example "Tank vent":
Unfasten hose clip (1).
Do not release hose clamp (2).

Detach lines from hoses.

Installation:
Replace hose clamps.
Tightening Torque
7AZ Hose clamps 10 - 16 mm dia. 2 Nm
9AZ Hose clamps 37 - 43 mm dia. 4 Nm







Support fuel tank on left fuel tank half.

NOTE: When supporting fuel tank, tightening straps must not be covered.







Release screw (1) for fuel tank mounting, rear right.
Tightening Torque
1AZ Tension strap to body (hexagon screw)
E53, E46, E85, E83, E87
M8 19 Nm

Unhook and remove tightening strap.







Release screw (1) for fuel tank mounting, rear left.
Tightening Torque
1AZ Tension strap to body (hexagon screw)
E53, E46, E85, E83, E87
M8 19 Nm






Release screw (1) for fuel tank mounting, center.
Tightening Torque
1AZ Tension strap to body (hexagon screw)
E53, E46, E85, E83, E87
M8 19 Nm

Unhook and remove tightening straps.

Installation:







Note rubber mount with spacer bush on tightening strap screw connections.
Wide collar on spacer bush faces towards screw head.







Note shim on both locating lugs.







Carefully lower fuel tank approx. 20 cm.







Remove line bundle (1) from wheel arch.
Carefully lower fuel tank further and set down.