Removal and Replacement
Replacing the fuel tank
Special tools:
999 5720 Wrench 999 5720 Wrench
Preparation
Note! On cars up to chassis number 104221 the fuel filler pipe must be replaced when the fuel tank is replaced.
Drain the fuel from the lines. See Draining the fuel system Draining the Fuel System.
Drain the fuel tank. See Draining the fuel tank Draining the Fuel Tank.
Removing the rear exhaust system
Raise the car.
Remove:
- both the rear wheels
- the front section of the exhaust system.
Removing the heat deflector plate
Remove the rear plastic nut from the left-hand fender liner.
Drill out the pop rivets which hold the heat deflector plate at the rear sub-frame mounting and the exhaust system bracket.
Remove:
- the plastic nuts holding the heat deflector plate
- the heat deflector plate.
Exposing the fuel tank
Remove:
- the plastic pipe with the largest connection to the carbon filter container. Position the pipe forwards towards the fuel tank
- the screws on the center and left mountings of the heat deflector plate for the fuel tank
- the brake pipe from the clip in the front edge of the tank
- the fuel filter from the bracket
- the hose clamp from the fuel filler pipe and the bleed pipe.
Removing the brakes
Remove:
- the mounting screws for the brake caliper. Hang the brake caliper in a suitable way
- the locating pins for the brake discs
- the brake discs.
Hint: If necessary release the parking brake shoes. See Handbrake, brake shoes, replacing Hand Brake, Brake Shoes, Replacing
Removing the parking brake cable
Remove:
- the return spring at the expander
- the expander. Lift the brake shoe slightly
- unhook the expander from the cable mounting.
Remove the guide sleeve for the cable sleeve.
Use a screwdriver. Pry carefully between the guide sleeve lug and the spindle.
Remove the parking brake cable from the tie rod and sub-frame. Bend the parking brake cables forward. Hang the parking brake cable from the front SIPS member.
Lowering the fuel tank
Position a lifting table under the fuel tank.
Remove the tank retaining strap screws. Lower the fuel tank slightly.
Remove:
- The ABS lines from the clips
- The fuel filler pipe and the bleed pipe from the fuel tank terminals.
Lower the fuel tank slightly further.
Remove:
- fuel lines
- the plastic pipe between the carbon filter container and the evaporative emission system (EVAP) valve from the upper side of the tank.
Lower the tank completely.
Note! Check that the lines and wiring are unimpeded during the rest of the lowering of the tank.
Applies only to cars with chassis numbers below 104221.
Replace the fuel filler pipe. See Replacing the fuel filler pipe (When replacing the fuel tank) Service and Repair.
Transferring components
Removing the fuel tank pressure valve
Disconnect the hose (hose clamp).
Remove:
- the screw
- the valve.
Removing the splash guard pipe
Remove the splash guard pipe. Pull straight out.
Removing the level sensor
Lift the left level sensor.
Remove:
- the connector
- the ejector.
Grip the right-hand level sensor / pump. Pinch the float to hold it in its lowest position.
Carefully and slowly pull up the holder. Carefully work the holder out.
Pull the hoses and the wiring out of the tank.
Note! Take care with the fuel tank.
Note! It is extremely important that the float arm is not broken or bent.
Removing the tank retaining strap and heat deflector plate
Remove:
- the screws (x 2)
- the tank retaining strap
- the screws (x 2)
- the heat deflector plate.
Installing the tank retaining strap and heat deflector plate
Install:
- the heat deflector plate
- the 2 screws. Tighten to 5 Nm
- the tank retaining strap
- the 2 screws. Tighten to 10 Nm.
Installing the level sensor
Install the sealing ring.
Route the cable harness / hoses from the right level sensor to the left side of the tank as illustrated.
Hint: Use a welding rod bent into a curve with a hook at one end to pull the cable harness / hoses to the correct position.
Note! It is very important for installing the level sensor that the cable harness / hoses are routed into the front section of the fuel tank.
Install on the left-hand side:
- sealing cover
- the ejector
- the connectors
- the level sensor. Tighten to 60 Nm. (Use special tool 999 5720 Wrench 999 5720 Wrench ).
Note! Ensure that the arrow is opposite the marking on the tank.
Install on the right-hand side:
- the level sensor. Tighten to 60 Nm. (Use special tool 999 5720 Wrench 999 5720 Wrench ).
Ensure that the arrow is opposite the marking on the tank.
Installing the splash guard pipe
Install the splash guard pipe.
Note! Ensure that the locating pin is correctly positioned for the groove in the tank.
Installing the fuel tank pressure valve
Install:
- the valve
- the screw
- the hose (hose clamp).
Installing the fuel tank
Position the fuel tank on the lifting table. Raise the fuel tank to a suitable height so that the fuel lines and plastic pipes between the carbon filter container and the evaporative emission system (EVAP) valve can be positioned in their terminals on the upper side of the fuel tank.
Connect the fuel lines to the right level sensor / pump as illustrated.
Route the electrical wiring to the passenger compartment through the floor.
Lift the fuel tank up completely.
Ensure that no lines or wiring are trapped. Install the fuel filler pipe and the bleed pipe on the fuel tank at the same time.
Twist the hose clamps so that they can be easily tightened later.
Note! Always use new hose clamps.
Install the ABS wiring in its clips.
Tighten the tank retaining strap screws. Tighten to 25 Nm.
Install the fuel filter and console. Tighten to 25 Nm.
Installing the brakes
Install:
- the parking brake cable along the heat shields
- the screws in the center and front mountings for the heat shield.
Install:
- the parking brake cables on the wheel units
- the parking brake cable mountings in the sub-frame. (25 Nm)
- the mounting for the parking brake cable on the track rods.
Press the guide sleeves for the parking brake cables into place on the wheel units.
Hint: Lubricate the O-rings on the guide sleeves. Use lubricant 1161580 or silicon grease.
Install:
- the expander on the cable. Press the mounting together to lock the cable in the expander
- the expander between the brake shoes
- the return spring.
Check the function.
Install:
- the brake disc and the locating pin. Tighten to 10 Nm
- the brake caliper. Use new screws. Tighten to 60 Nm.
Note! If necessary, adjust the parking brake. See Handbrake, brake shoes, replacing Hand Brake, Brake Shoes, Replacing
Install the plastic pipe from the fuel tank with the large connector on the carbon filter container.
Note! A click should be heard when the connector is pressed into place.
Installing the heat deflector plate
Position the heat deflector plate over the rear muffler. Install the plastic nuts and the rear pop rivet. Install the pop rivets on the rear mounting of the sub-frame.
Install the rear wheels. See Installing wheels Service and Repair.
Installing exhaust system
Install the exhaust system. Use a new flange gasket. Tighten the screws. Tighten to 25 Nm.
Finishing
Install:
- the 2-3 connectors on the right side and the 2 connectors on the left side
- the cover over the level sensors. Check that the wiring is correctly located in the groove in the rubber gaskets around the hole in the floor
- insulation panel
- the backrest.