Removal and Replacement
Removing And Installing Fuel Tank
Tools
Technical values
Preliminary work
Preliminary work - Carrera 2
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapors.
- Attach warning sign in a clearly visible position.
INFORMATION: Set the steering wheel with the wheels in straight-ahead position. If this is not done, the airbag contact unit will have to be put in centre position after installation of the steering gear.
1. Raise the vehicle at the prescribed jacking points.
DANGER:
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
- Do not place any solid objects under the raised vehicle.
- Ensure that the lifting platform is prevented from lowering.
- Remove solid objects before lowering the vehicle.
- Raise the vehicle only at the take-up points provided.
2. Place a warning sign in a clearly visible position in the work area or on the vehicle.
3. Place protective covers on the vehicle.
4. Move steering wheel into centre position. Use the steering-wheel holder -A- to secure the steering wheel in centre position.
INFORMATION:
- Use only steering wheel holders that do not project into the area of the airbag unit.
- If necessary, shorten guide rod at top.
5. Remove front wheels.
Use special tool socket-wrench insert P 300 to avoid damaging the rims.
6. Disconnect and remove the battery.
7. Remove carrier plate for battery. Unscrew four M8 nuts and remove the lid. Check seal for damage and replace it if necessary.
8. Remove fuel level sensor.
9. Empty the fuel tank. Fuel transfer unit WE WE1262 should be used. - Emptying and filling the fuel tank
10. Remove rear part of front right wheel housing liner.
11. Remove filler neck
12. Remove underbody panelling.
13. Remove holder for coolant pipes -2- in the centre tunnel.
Unscrew four hexagon-head bolts -1- and unclip plastic holders on the coolant pipes and vent line -arrows-.
14. Remove the diagonal braces.
(Observe marking: R = Right, L = Left)
14.1. Remove diagonal braces -1-. Unscrew screws -2- and remove diagonal braces -2-.
14.2. Remove crash stop (all-wheel drive only). Loosen and remove screws -4- and then remove the crash stop -3-.
15. Remove restraining straps on the fuel tank.
15.1. Loosen and remove screws -2- and then remove the restraining straps -1-.
15.2. Remove fuel tank cover.
15.3. Re-insert and screw on restraining straps -1-. Only tighten screws -2- hand-tight.
16. Remove universal joint at the steering spindle.
16.1. Precondition: Steering wheel must be in centre position.
16.2. Remove universal joint.
Make sure not to pull the red lug -4- off as well because this will only increase the amount of assembly work required.
Loosen screw -1- on the universal joint -2- and remove it. Pull universal joint -2- off the steering spindle -3-
17. Remove front-axle cross member.
18. Disengage coolant pipes and secure with tie-wraps.
Preliminary work - Carrera 4
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapors.
- Attach warning sign in a clearly visible position.
DANGER:
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
- Do not place any solid objects under the raised vehicle.
- Ensure that the lifting platform is prevented from lowering.
- Remove solid objects before lowering the vehicle.
- Raise the vehicle only at the take-up points provided.
1. Raise the vehicle at the prescribed jacking points.
2. Place a warning sign in a clearly visible position in the work area or on the vehicle.
3. Place protective covers on the vehicle.
4. Move steering wheel into centre position.
Use the steering-wheel holder -A- to secure the steering wheel in centre position.
INFORMATION:
- Use only steering wheel holders that do not project into the area of the airbag unit.
- If necessary, shorten guide rod at top.
5. Remove front wheels.
Use special tool socket-wrench insert P 300 to avoid damaging the rims.
6. Disconnect ground cable on the battery.
7. Remove fuel level sensor.
8. Empty the fuel tank. Fuel transfer unit WE WE1262 should be used.
9. Remove rear part of front right wheel housing liner.
10. Remove filler neck.
11. Remove underbody panelling.
12. Remove the cardan shaft.
13. Remove support for final drive.
13.1. Disengage pipe holder from lines and remove it.
Remove the pipe holder -1- by pulling off the cable plug -2- and pulling off the grab handles -arrows- on the coolant pipes.
13.2. Unscrew screws securing support for final drive -A-. Never loosen screw on transmission mount -B-.
14. Remove diagonal braces and crash stop.
(Observe marking: R = Right, L = Left)
14.1. Remove diagonal braces -1-.
Unscrew screws -2- and remove diagonal braces -1-.
14.2. Remove crash stop (all-wheel drive only).
Loosen and remove screws -4- and then remove crash stop -3-.
15.1. Loosen and remove screws -2- and then remove the restraining straps -1-.
15.2. Remove fuel tank cover.
15.3. Re-insert and screw on restraining straps -1-. Only tighten screws -2- hand-tight.
16. Remove front final drive.
17. Remove drive shafts on the transmission side.
Remove drive shafts -1- at the front by loosening and unscrewing twelve M8 screws.
INFORMATION:
- Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).
- Set the steering wheel with the wheels in straight-ahead position. If this is not done, the airbag contact unit will have to be put in centre position after installation of the steering gear.
18. Remove universal joint at the steering spindle.
18.1. Precondition: Steering wheel must be in centre position.
18.2. Remove universal joint.
Make sure not to pull the red lug -4- down as well because this will only increase the amount of assembly work required.
Loosen screw -1- on the universal joint -2- and remove it. Pull universal joint -2- off the steering spindle -3-.
19. Remove front-axle cross member.
20. Secure coolant pipes with tie-wraps.
Removing fuel tank
Removing fuel tank - Carrera 2
Overview of the Carrera 2
1. Remove transverse restraining strap.
Unscrew two M8 screws -2- securing the transverse restraining strap -1- to the body at the left and right.
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapors.
- Attach warning sign in a clearly visible position.
INFORMATION: Get another person to help you remove and install the fuel tank.
2. Remove the fuel tank.
Unclip the two clips -arrows- on the body and lift the fuel tank out of the vehicle with the help of another person. To do this, first tip the fuel tank to the right. Be careful of the tank flange.
Removing fuel tank - Carrera 4
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapors.
- Attach warning sign in a clearly visible position.
Overview of the Carrera 4
1. Remove transverse restraining strap.
Unscrew two M8 x 40 screws securing the transverse restraining strap to the body at the left and right.
2. Unclip the two clips on the body -arrows-.
INFORMATION: Get another person to help you remove and install the fuel tank.
3. Remove the fuel tank.
To do this, first tip the fuel tank back and carefully guide the tank flange past the edge of the body -arrow-.
4. Check foam parts for damage and replace them if necessary.
Installing fuel tank
Installing fuel tank - Carrera 2
INFORMATION: Get another person to help you remove and install the fuel tank.
1. Install the fuel tank.
1.1. Guide the fuel tank into the body with the help of a second person. Clip clips into the body mounting points.
1.2. Insert transverse restraining strap at the correct position on the tank and secure with two M8 x 40 screws.
Tightening torque: 23 Nm (17 ftlb.)
Installing fuel tank - Carrera 4
INFORMATION: Foam parts must be fitted on the fuel tank. Affix new parts to the specified positions if necessary.
1. Affix foam part -1- to the tank flange of the fuel tank if necessary.
Side view
2. Affix foam part -2- for the bulkhead if necessary.
INFORMATION: Get another person to help you remove and install the fuel tank.
3. Install the fuel tank.
3.1. Clip clips into the body mounting points.
3.2. Insert transverse restraining strap at the correct position on the tank and secure with two M8 screws.
Tightening torque: 23 Nm (17 ftlb.)
Subsequent work
Subsequent work - Carrera 2
1. Install front-axle carrier.
2. Fit universal joint at the steering spindle. Use new fastening screw.
2.1. Precondition: Steering wheel must be in centre position.
2.2. Fit universal joint on the steering spindle.
Fit universal joint on the steering spindle while paying attention to the installation position -see arrows-.
2.3. Screw in and tighten M8 screw -arrow- on the universal joint.
Tightening torque: 23 Nm (17 ftlb.)
3. Fit restraining straps on the fuel tank.
Observe installation position (left to right).
Fit restraining straps -1- and screw in and tighten screws -2-.
Tightening torque: 23 Nm (17 ftlb.)
4. Install diagonal braces.
4.1. Install diagonal braces -1-.
Fit diagonal braces -1- and screw in and tighten screws -2-.
Tightening torque: 100 Nm (74 ftlb.)
5. Fit support for final drive.
Tightening torque: 65 Nm (48 ftlb.)
6. Install plastic holder for coolant pipes.
7. Install filler neck.
8. Install fuel level sensor.
9. Fuel the vehicle.
10. Install carrier plate for battery.
Tightening torque: 23 Nm (17 ftlb.).
11. Install the battery.
12. Start the vehicle.
13. Check all lines and connections for leaks.
14. Install rear part of front right wheel housing liner.
15. Install underbody panelling.
16. Install front wheels.
17. Remove steering-wheel holder.
18. Perform suspension alignment.
19. Perform a test drive.
Subsequent work - Carrera 4
1. Install front-axle carrier.
2. Install front final drive.
3. Fit support for final drive.
3.1. Engage pipe holder on lines.
Press on grab handles -arrows- on the coolant pipes and connect cable plug -2-. Slide the pipe holder -1- back until it engages on the support for final drive.
3.2. Secure support for final drive. Screw in and tighten screws -arrows-.
Tightening torque: 65 Nm (48 ftlb.)
4. Install cardan shaft.
5. For all-wheel drive vehicles: Fit the drive shafts on the transmission side.
Fit drive shafts -1- at the front by screwing in and tightening the screws.
Tightening torque: 39 Nm (29 ftlb.)
6. Fit universal joint at the steering spindle. Use new fastening screw.
6.1. Precondition: Steering wheel must be in centre position.
6.2. Fit universal joint on the steering spindle.
Fit universal joint on the steering spindle while paying attention to the installation position -see arrows-.
6.3. Screw in and tighten M8 screw -arrow- on the universal joint.
Tightening torque: 23 Nm (17 ftlb.)
7. Fit restraining straps on the fuel tank.
Observe installation position (left to right).
Fit restraining straps -1- and screw in and tighten screws -2-.
Tightening torque: 23 Nm (17 ftlb.)
8. Install diagonal braces. Diagonal brace (shown on the C4)
8.1. Install diagonal braces -1-.
Fit diagonal braces -1- and screw in and tighten screws -2-.
Tightening torque: 100 Nm (74 ftlb.)
9. Install filler neck.
10. Install fuel level sensor.
11. Connect the battery.
12. Start the vehicle.
13. Fuel the vehicle.
14. Check all lines and connections for leaks.
15. Install rear part of front right wheel housing liner.
16. Install underbody panelling.
17. Install front wheels.
18. Remove steering-wheel holder.
19. Perform suspension alignment.
20. Perform a test drive.