Removal and Replacement

WM 201019 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 vapours.
-> 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.
-> 4X00IN01 Lifting the vehicle

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.
-> The outer take-up points should be used primarily.

2. Place a warning sign in a clearly visible position in the work area or on the vehicle.

Example of warning sign

3. Place protective covers on the vehicle.
4. Move steering wheel into centre position.

Steering-wheel holder

Use the steering-wheel holder -A- to secure the steering wheel in centre position.

Information

- Use only steering wheel holders -A- that do not project into the area of the airbag unit -B-.

- If necessary, shorten guiding rod at the top -arrow-.

Steering-wheel holder (example shown)

5. Remove front wheels.
Use special tool socket-wrench insert P 300 to avoid damaging the rims.
-> 44051900 Removing and installing wheel - section on "Removing" 440519 Removing and installing wheel
6. Disconnect and remove the battery.
-> 270619 Removing and installing battery - section on "Removing" 27061900 Removing and installing 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.
-> 201519 Removing and installing fuel level sensor - section on "Removing" Service and Repair
9. Empty the fuel tank.
Fuel transfer unit WE WE1262 should be used.
-> 2010EN Emptying and filling the fuel tank
10. Remove rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
11. Remove filler neck.
-> 200719 Removing and installing filler neck - section on "Removing" Service and Repair
12. Remove underbody panelling.
-> 519419 Removing and installing rear cover - Removing 519419 Removing and Installing Cover for Rear Underbody
-> 519320 Removing and installing centre cover - section on "Removing" 519319 Removing and Installing Cover for Centre Underbody
-> 519219 Removing and installing front cover - section on "Removing" 519219 Removing and installing Cover For Front Underbody
13. Remove holder for coolant pipes -2- in the centre tunnel.

Holder for coolant pipes

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)

Diagonal braces (shown on Carrera 4)

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.

Removing and installing restraining straps (shown on Carrera 4)

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.

Removing and installing 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.
-> 400919 Removing and installing front-axle cross member - section on "Removing".
18. Disengage coolant pipes and secure with tie-wraps.

Disengaging coolant pipes

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 vapours.
-> 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.
-> The outer take-up points should be used primarily.

1. Raise the vehicle at the prescribed jacking points.
-> 4X00IN01 Lifting the vehicle
2. Place a warning sign in a clearly visible position in the work area or on the vehicle.

Warning sign for naked flames

3. Place protective covers on the vehicle.
4. Move steering wheel into centre position.

Steering-wheel holder

Information

- Use only steering wheel holders -A- that do not project into the area of the airbag unit -B-.

- If necessary, shorten guiding rod at the top -arrow-.

Steering-wheel holder (example shown)

Use the steering-wheel holder -A- to secure the steering wheel in centre position.
5. Remove front wheels.
Use special tool socket-wrench insert P 300 to avoid damaging the rims.
-> 44051900 Removing and installing wheel - section on "Removing" 440519 Removing and installing wheel
6. Disconnect ground cable on the battery.
-> 2706IN Work instructions after disconnecting the battery
7. Remove fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Removing" Service and Repair
8. Empty the fuel tank.
Fuel transfer unit WE WE1262 should be used.
-> 2010EN Emptying and filling the fuel tank
9. Remove rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
10. Remove filler neck.
-> 200719 Removing and installing filler neck - section on "Removing" Service and Repair
11. Remove underbody panelling.
-> 519419 Removing and installing rear cover - Removing 519419 Removing and Installing Cover for Rear Underbody
-> 519320 Removing and installing centre cover - section on "Removing" 519319 Removing and Installing Cover for Centre Underbody
-> 519219 Removing and installing front cover - section on "Removing" 519219 Removing and installing Cover For Front Underbody
12. Remove the cardan shaft.
-> 390219 Removing and installing cardan shaft - section on "Removing"
13. Remove support for final drive.
13.1. Disengage pipe holder from lines and remove it.

Removing pipe holder

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-.

Support for final drive

Never loosen screw on transmission mount -B-.
14. Remove diagonal braces and crash stop.
(Observe marking: R = Right, L = Left)

Diagonal braces

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. Remove restraining straps on the fuel tank.

Removing and installing restraining straps

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.
-> 398819 Removing and installing front final drive - section on "Removing".
17. Remove drive shafts on the transmission side.

Removing and installing drive shaft

Information

Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).

Remove drive shafts -1- at the front by loosening and unscrewing twelve M8 screws.

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.

18. Remove universal joint at the steering spindle.
18.1. Precondition: Steering wheel must be in centre position.
18.2. Remove universal joint.

Removing and installing 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.
-> 400919 Removing and installing front-axle cross member - section on "Removing".
20. Secure coolant pipes with tie-wraps.

Releasing coolant pipes

Removing fuel tank

Removing fuel tank - Carrera 2

Overview of the Carrera 2

Overview of C2 fuel tank

1. Remove transverse restraining strap.

Fuel tank restraining strap, transverse

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 vapours.
-> 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.

Clips securing 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 vapours.
-> Attach warning sign in a clearly visible position.

Overview of the Carrera 4

Component overview: C4 fuel tank

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-.

Clips securing fuel tank

Information

Get another person to help you remove and install the fuel tank.

3. Remove the fuel tank.

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.

Position of foam part on tank flange

Side view

Side view of foam part on tank flange

2. Affix foam part -2- for the bulkhead if necessary.

Foam part for bulkhead

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.
-> 400919 Removing and installing front-axle carrier - section on "Installing"
-> 4001TW Tightening torques for front axle
2. Fit universal joint at the steering spindle. Use new fastening screw!
-> 489019 Removing and installing power-steering gear - section on "Installing" Service and Repair.
2.1. Precondition: Steering wheel must be in centre position.

Steering-wheel holder

2.2. Fit universal joint on the steering spindle.

Universal joint for steering gear

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.

Universal joint

=> Tightening torque: 23 Nm (17 ftlb.)
3. Fit restraining straps on the fuel tank.

Restraining straps (shown on the C4)

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.

Diagonal brace (shown on the C4)

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.
-> 200719 Removing and installing filler neck - section on "Installing" Service and Repair
8. Install fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Installing" Service and Repair
9. Fuel the vehicle.
-> 2010EN Emptying and filling the fuel tank
10. Install carrier plate for battery.
=> Tightening torque: 23 Nm (17 ftlb.).
11. Install the battery.
-> 270619 Removing and installing battery - section on "Installing" 27061900 Removing and installing battery
12. Start the vehicle.
13. Check all lines and connections for leaks.
14. Install rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
15. Install underbody panelling.
-> 519319 Removing and installing centre cover - section on "Installing" 519319 Removing and Installing Cover for Centre Underbody
-> 519419 Removing and installing rear cover - Installing 519419 Removing and Installing Cover for Rear Underbody
-> 519219 Removing and installing front cover - section on "Installing" 519219 Removing and installing Cover For Front Underbody
16. Install front wheels.
-> 44051900 Removing and installing wheel - section on "Installing" 440519 Removing and installing wheel
17. Remove steering-wheel holder.
18. Perform suspension alignment.
-> 44950300 Suspension alignment, complete
19. Perform a test drive.

Subsequent work - Carrera 4

1. Install front-axle carrier.
-> 400919 Removing and installing front-axle carrier - section on "Installing"
-> 4001TW Tightening torques for front axle
2. Install front final drive.
-> 398819 Removing and installing front final drive - section on "Installing"
3. Fit support for final drive.
3.1. Engage pipe holder on lines.

Installing pipe holder

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.

Support for final drive

Screw in and tighten screws -arrows-.
=> Tightening torque: 65 Nm (48 ftlb.)
4. Install cardan shaft.
-> 390219 Removing and installing cardan shaft - section on "Installing"
5. For all-wheel drive vehicles: Fit the drive shafts on the transmission side.

Removing and installing drive shaft

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!
-> 489019 Removing and installing power-steering gear - section on "Installing" Service and Repair.
6.1. Precondition: Steering wheel must be in centre position.

Steering-wheel holder

6.2. Fit universal joint on the steering spindle.

Universal joint for steering gear

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.

Universal joint

=> Tightening torque: 23 Nm (17 ftlb.)
7. Fit restraining straps on the fuel tank.

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.
-> 200719 Removing and installing filler neck - section on "Installing" Service and Repair
10. Install fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Installing" Service and Repair
11. Connect the battery.
-> 2706IN Work instructions after disconnecting the battery
12. Start the vehicle.
13. Fuel the vehicle.
-> 2010EN Emptying and filling the fuel tank
14. Check all lines and connections for leaks.
15. Install rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair.
16. Install underbody panelling.
-> 519319 Removing and installing centre cover - section on "Installing" 519319 Removing and Installing Cover for Centre Underbody
-> 519419 Removing and installing rear cover - Installing 519419 Removing and Installing Cover for Rear Underbody
-> 519219 Removing and installing front cover - section on "Installing" 519219 Removing and installing Cover For Front Underbody
17. Install front wheels.
-> 44051900 Removing and installing wheel - section on "Installing" 440519 Removing and installing wheel
18. Remove steering-wheel holder.
19. Perform suspension alignment.
-> 44950300 Suspension alignment, complete
20. Perform a test drive.