Fuel Tank: Service and Repair
Removing And Installing Fuel Tank
Tools
WARNING: Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels.
CAUTION:
Coolant is hazardous to the health and irritates the skin. Danger of scalding when the engine is hot. Do not begin working until the engine has cooled down.
- When handling coolant, wear protective gloves and goggles.
- In case of contact with the skin or eyes, wash immediately with plenty of water.
Removing fuel tank
INFORMATION: To lock the steering wheel, use only the steering wheel holder -A- approved for airbags to prevent damage or injury should an airbag be released.
1. Move steering wheel to centre position (front wheels straight-ahead) and lock it with the steering wheel holder -arrow- .
INFORMATION: Before disconnecting the battery, observe the work instructions
2. Disconnect battery. Disconnect negative terminal and cover the terminal or battery.
3. Remove the front wheels, using the prescribed special tool socket wrench insert p 300 to avoid damage to the wheels.
4. Remove front wheel housing liner.
INFORMATION:
- It is impermissible to suck out the fuel through the filler neck, as this can damage the inner flap on the filler neck. Always suck out the fuel through the hole for the fuel level sensor.
- Remove fuel level sensor.
5. Empty the fuel tank. The fuel must be sucked out through the hole for the fuel level sensor. To do this, remove the closure cap in the luggage compartment (unscrew four hexagon nuts a/f 10) and disconnect all cable plugs and fuel lines from the fuel level sensor. Undo union nut with special tool socket wrench 3217 , carefully remove the fuel level sensor and place in a clean container, e.g. a bucket. Remove the fuel using a suitable fuel extractor. Cover hole for the fuel level sensor with a cloth or similar.
INFORMATION: To remove and install the front wheel drive the help of a second person is necessary
6. Remove the front-wheel drive complete with cardan shaft. Get a second person to help.
7. Drain coolant. To do this, clamp shut the coolant hoses between the cardan tunnel and the engine (including the black vent line over the left coolant pipe) with hose clamps. Drain coolant at the radiator drain plug.
8. Re-tighten drain plugs. Undo the coolant pipes and vent line at the cardan tunnel. To do so, slide off the spring-band clamps at the rear using spring-band clamp pliers, unclip from the plastic holders, and unscrew the two hexagon-head bolts M6 -Item 1- and the two hexagon nuts M6 -Item 3- at the front pipe holder. Place a coolant collecting container ready, secure the pipes with wire and then pull from the rear coolant hoses. Collect the draining coolant and allow pipes to drain.
9. Detach tank filler neck. To do so, remove closure cap and unscrew the hexagon bolt M6 x 12 -arrow- .
10. Unclip seal of the filler neck in the right front wheel well -1- . Disconnect plug connections for the vent lines at the filler neck -2- . Press release buttons and simultaneously pull the lines apart. Disconnect ground strap -4- on the plug. Disconnect vent line to fuel tank -3- behind the spring strut.
INFORMATION: To avoid damage to the wing when removing and installing the filler neck, suitable protective covers must be placed.
11. Turn the filler neck clockwise by approx. 45° and pull out carefully. The open surge flap must not be damaged when pulling out the filler neck. Close the opening in the fuel tank (e.g.with the cap of a spray can).
12. Loosen universal joint (steering shaft) -arrow- at steering gear. Take out the fit bolt M8 x 35 and slide the universal joint upwards. If necessary, carefully force apart the clamping piece with a screwdriver and spray with rust solvent. Replace fit bolt.
INFORMATION: The suspension subframe must be lowered. To do this, undo the two screws fastening the steering gear to the suspension subframe.
13. Detach steering gear from the suspension subframe. To do this, unscrew the two hexagon-head bolts M10 x 1.5 a/f 15 (on the underside of the suspension subframe) -5- and press off the steering gear.
14. Support suspension subframe with a transmission jack. Pull off the cable plug on the sensor of the headlight beam adjustment -right arrow- . Detach stabilizer from the mount. To do this, remove the hexagon nut M10 from each joint -left arrow in the Figure- , countering with an open-ended wrench at the joint hexagon.
15. Detach suspension subframe. Undo the six hexagon-head bolts at the front and rear -Items 2, 6 and 7- and lower complete suspension subframe by approx. 15 cm.
16. Disconnect all coolant lines. To do this, undo the four spring-band clamps -Item 4, upper part of Figure- on the coolant hoses at the front and pull off the coolant pipes.
17. Undo a spring-band clamp for the vent line on the distributor hose in the left front wheel well -1- . Remove coolant pipe.
18. Pull off vent line from distributor hose in the left front wheel well -Item 2, previous Figure- and unclip from the two holders under the fuel tank -arrow- . Remove line on the coolant hose in the right front wheel well by undoing the spring-band clamps. If necessary, collect the draining coolant. Pull off vent line to the side.
INFORMATION: Observe the installation position of both connector tubes to the radiators in relation to the plastic holders.
19. Disconnect both connector tubes to the radiators under the fuel tank and remove. To do this, undo hose clamps on the coolant hoses.
20. Remove both plastic holders complete with coolant pipes from the body. To do this, pull back the tab on each holder -2- , press the entire holder forwards and up -3- and remove the pipe package together with both holders to the rear. Remove pipes from the plastic holders in the wheel wells. Observe installation position of the coolant pipes.
21. Detach fuel tank restraining strap (transverse) from the body by unscrewing the two hexagon-head bolts M8 x 40 -arrow- .
22. Lift the fuel tank from the support lugs -arrows- and, with the help of a second person, carefully remove in a downward direction (avoiding damage to the hole for the fuel level sensor).
Installing fuel tank
INFORMATION:
- Fix connecting cable and fuel lines, using adhesive tape if necessary, to the body aperture for the fuel level sensor
- Observe line routing between fuel tank and body (e.g. chafing, pinching)
1. Lift the fuel tank with the help of a second person and carefully insert from below (avoiding damage to the hole for the fuel level sensor). Engage fuel tank on the support lugs on the floor of the body -arrows- .
2. Install fuel tank restraining strap (transverse). Position hexagon bolts M8 x 40 at the sides of the body and tighten -arrow- .
Tightening torque: 23 Nm (17 ftlb.)
3. Insert fuel level sensor with new seal into fuel tank. Position and tighten new union nut. Fit lines and plugs. After assembly, secure union nut with a spot of hot-melt adhesive. Fit closure cap in the luggage compartment (screw tight the four hexagon nuts a/f 10).
Tightening torque for union nut 70 Nm (52 ftlb.)
4. Pre-position connector tubes to the radiators together with pre-mounted holders (replace if necessary) in installation position under the fuel tank. Clip holders to the body. To do this, hook the holders at the front and engage the tab at the rear. Push the left and right pipes into coolant hoses and tighten screw-type hose clamps.
5. Insert vent line into distributor hose in the left front wheel well -2- and into coolant hose in the right front wheel well and fit the spring-band clamps.
6. Clip vent line into the two holders -arrows- on the coolant pipes.
7. Fasten coolant pipes at front. To do this, insert two aluminium pipes and a vent line in the network into the corresponding coolant hoses and fit the five spring-band clamps (1 clamp for vent line on the distributor hose in the left front wheel well -Item 2- and four clamps for coolant pipes -Item 4 in next figure- ).
8. Mount four pipe holders using two M6 hexagon-head bolts and two M6 hexagon nuts -Items 1 and 3 in next Figure- and fix coolant pipes on the vehicle underbody in the holders. Push coolant pipes into the coolant hoses to the engine, tighten the spring-band clamps and remove the hose clamps again.
Tightening torque of the hexagon-head bolts M6: 10 Nm (7.5 ftlb.)
INFORMATION: When lifting the suspension subframe, protect servo lines of the steering from damage
9. Carefully lift suspension subframe and fix with the six hexagon-head bolts -Items 2, 6 and 7- . Screw suspension subframe into place to the prescribed tightening torque.
Tightening torque M14 x 1.5 : 160 Nm (118 ftlb.) ( -Item 2- )
Tightening torque of corner plate to side member M10 x 1.5 : 65 Nm (48 ftlb.) ( -Item 6- )
Tightening torque of corner plate to body M12 x 1.5 : 100 Nm (74 ftlb.) ( -Item 7- )
10. Fit stabilizer to mount -left arrow- . To do this, screw two M10 hexagon nuts on the joint heads, simultaneously countering at the joint hexagon with an open-ended wrench. Connect cable plug to sensor of the headlight beam adjustment -right arrow- .
Tightening torque of M10 hexagon nut: 46 Nm (34 ftlb.)
INFORMATION: Replace hexagon-head bolts for fastening the steering gear to the suspension subframe and the fit bolt for the universal joint whenever they have been removed. Screw threads must be clean and free of grease.
11. Position the steering gear with the centring sleeves in the thorough-holes on the suspension subframe and screw into place with two new hexagon-head bolts a/f 15 M10 x 1.5 to the underside of the suspension frame -5-.
Tightening torque 65 Nm (48 ftlb.).
INFORMATION: The lug on the toothed steering gear pin must engage in the clamping slot of the universal joint -arrows- .
12. Push universal joint of the steering shaft onto the toothed steering gear pin. The lug must engage in the clamping slot of the universal joint. Insert new fit bolt M8 x 35 into the retaining groove -arrow- and tighten with the prescribed torque.
Tightening torque: 23 Nm (17 ftlb.)
13. Install the front wheel drive with the help of a second person
INFORMATION: To facilitate installation, apply a thin coat of silicone spray to the filler neck in the fitting area.
14. Fit filler neck. Remove protective cap on fuel tank. Carefully push the filler neck with rotary movements into the flange on the fuel tank (protect wing and wheel well from damage). Fit vent lines and ground cable -Items 2, 3 and 4 in the next figure- by connecting to the filler neck.
15. Fit seal in correct position -1- . Ensure that the locking tabs are seated correctly.
16. Tighten hexagon-head bolt M6 x 12 of the filler neck -arrow- . Coat seat of the cap seal with Vaseline.
Tightening torque 10 Nm (7.5 ftlb.)
17. Fill and bleed cooling system.
18. Refill fuel tank.
19. Calibrate fuel level sensor system.
20. Install front wheel housing liners.
INFORMATION: Observe specification for greasing wheel bolts.
21. Fit the front wheels, using the prescribed special tool socket wrench insert p 300 to avoid damage to the wheels.
Tightening torque of the wheel bolts : 130 Nm (96 ftlb.).
22. Connect the battery.
23. Remove steering wheel holder.
24. Check wheel arch values. In the case of deviations, perform a suspension alignment if necessary and adjust.
Tightening torques for front axle and fuel tank
