Installing Fuel Tank
Installing Fuel Tank
Tools
Tools and materials
Required tools
General warning notes
Fuel supply, control
DANGER:
Danger of poisoning from fuels.
- Gasoline is toxic.
- Inhaling vapours can cause irritation of the mucous membranes and eyes.
- It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
- Only work on the fuel system in well-ventilated rooms.
- Wear protective gloves that are fuel-resistant.
- Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
- Ensure that there is adequate ventilation and extract all fuel vapours.
- Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
- Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
- Pay attention to cleanliness when working on the fuel system.
DANGER:
Danger of fire from fuel.
- Keep clear of ignition sources.
- Do not smoke.
- Disconnect battery.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO2 or dry powder fire extinguishers.
NOTE:
- The ignition must be switched off when working on the fuel system.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
Installing fuel tank
NOTE:
- The repair procedure may vary depending on engine type and country equipment. This relates in particular to components in the right wheel housing.
- The description relates to ORVR vehicles.
- Sealing rings must generally be replaced.
The following exploded drawing shows how the fuel tank is attached to the vehicle floor.
NOTE:
- The top left cover must be fitted before the tank is installed.
- When installing the tank and rear axle, make sure that cables and lines are not damaged and are in the correct installation position.
- When introducing the tank into the body, a second person should guide the degassing tank and safeguard it against damage using wire.
1. Raise the tank with a transmission jack. Make sure to secure the tank with a tension strap to prevent it from falling.
2. With the help of a second worker, put the tank into the installation position. A second person should carefully guide the degassing tank.
NOTE: Note direction arrow stamped on the restraining straps and install these in the direction of travel.
3. Attach lower covers and fit the four restraining straps, which run at right angles to the direction of travel. Make sure that the stamped arrow is pointing forwards in the direction of travel. Tighten fastening screws to the specified tightening torque. Tightening torque: 17 ftlb. Secure fuel filler neck and degassing tank again with a wire -arrow-.
4. Lower the transmission jack and fit the centre restraining strap. The arrow must be pointing forwards. Tighten fastening screws to the specified torque. Tightening torque: 17 ftlb.
5. Fit the exhaust system heat shield. If the shield is cracked or damaged, it must be replaced. Tighten the 3 sheetmetal nuts and the 2 screws.
6. Mount the underbody panel of the side member on the left and right.
7. Replace holder and attach to side member. Clip in lines.
8. Then, fit the stone guard on the right side. Mount nuts -arrows-and tighten to the specified torque. Tightening torque: 7.5 ftlb.
9. Mount the fuel supply -1- to the connection unit and connect the 2 connection points-2 and 3-.
Subsequent work
1. Fit cover. Tighten the 4 fastening nuts. Tightening torque: 7.5 ftlb. Refit carpeted floor and fix with double-sided adhesive tape.
2. Tighten the seat-belt buckle fastening plates. Use 3 new fastening screws for this and tighten.
3. Fold rear seat down again.
4. Mount rear axle (spring struts and rear axle housing).
5. Mount carbon canister.
6. Fill fuel tank (refuel).