Removal and Replacement

16 11 030 Removing And Installing Fuel Tank (Petrol)







IMPORTANT:
After installation of fuel tank/prior to first engine start-up:
- Check electrical resistance between metal filler bowl and wheel hub.
- Measured value: approx. 0.65 ohm.
- Fill fuel tank with at least 5 litres of fuel.







Necessary preliminary work:
- Draw off fuel from fuel tank.
- Remove underbody panelling of fuel tank at left and right.
- Remove exhaust system (front-wheel drive only)
- Remove propeller shaft (four-wheel drive only).
- Remove heat shield.
- Remove wheel arch panel at rear left.
- Detach parking brake Bowden cables at brake caliper at left and right.







Release bolts (2) from rear axle support.

Installation note:
Tightening torque 34 41 2AZ.

Disengage parking brake Bowden cables from brackets (1) and feed out through rear axle support.

NOTE: Parking brake Bowden cables remain attached to parking brake lever.







Release snap fastener (1) and disengage fuel filler neck breather pipe from bracket (2).

Installation note:
Ensure that snap fastener is locked correctly.







Release hose clamp (1) and remove filler hose from fuel tank.

Installation note:
Tightening torque 16 11 4AZ.







Unlock snap fastener (1) on carbon canister and detach.
Unlock snap fasteners (2) on carbon canister and detach.

Installation note:
Make sure snap fasteners engage correctly.







Detach snap fastener (1).
Disconnect snap fastener (2) of fuel delivery line.

Installation note:
Make sure snap fasteners engage correctly.

IMPORTANT: Secure fuel tank over a wide area with a suitable workshop jack and secure against falling down.












Release screw connections (1).
Release screw connections (2) and lower fuel tank a little.
Unclip tank ventilation line (3) at fuel tank.

Installation note:
Tank ventilation line (3) must correctly engage at fuel tank.

Replace self-locking nuts.
Tightening torque 16 11 3AZ.







Disconnect plug connection (1).
Pass filler neck breather pipe through body and slowly lower fuel tank.

Installation note:
Make sure that snap fastener is correctly engaged.

Make sure lines and wiring harness are not trapped or crushed during installation.







The following components must be modified when the fuel tank is replaced:
- Fuel pump
- Carbon canister