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Fuel tank

Fuel tank

Warning

Removal of the fuel tank involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:

• Work only in a well-ventilated area! If approved equipment for the extraction of fuel vapours is available, be sure to use it.

• Wear suitable gloves! Prolonged contact with fuel can cause skin irritation or dermatitis.

• Keep a class BE fire extinguisher near at hand! Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.

• No smoking anywhere in the vicinity.

• Wear protective goggles.


Dismantling


1. Drain the fuel from the tank.

Important

The tank must never be drained by suction through the filler pipe as this will damage the non-return valve!


2. Raise the car, making sure that the right-hand lift arm is situated as far to the right as possible so as not to be an obstruction during removal.


3. Detach the hose to the filler pipe from the tank and the purge line from the tank to the EVAP canister. Plug the tank.

4. Detach the quick-release coupling on the purge line to the filler pipe using tool 83 95 261.

5. Remove the protective cover from the fuel filter.

6. Undo the clamp securing the fuel filter.

7. Support the tank on a column lift, for example. Undo the nuts on the tank straps and unhook the straps.

8. Move the handbrake wire for the left-hand wheel to one side.

9. Carefully lower the tank, right-hand side first, until the top becomes visible.

10. Unplug the connectors to the fuel pump and tank pressure sensor (not present on stripped ORVR).


11. Remove the protective cap and detach the pressure and return lines from the fuel pump.

12. Detach the fuel lines from their retainers on the tank.

13. Lower the tank further to working height.


To fit



1. Place the tank on a column lift, for example.

2. Fit the fuel connections and protective cover and connect the cables to the fuel pump and tank pressure sensor (not present on stripped ORVR).

3. Move the handbrake cable for the left-hand wheel to one side and raise the tank slightly, the left-hand side first.

4. Secure the fuel lines in their retainers on the tank.

5. Raise the tank further up to its normal position and fasten the tank straps.

Note

Pay careful attention to the line from the tank to the EVAP canister.


6. Tighten the tank straps. The left-hand strap holds the handbrake wire.


7. Connect the line from the tank to the EVAP canister.

8. Screw on the fuel filter.

9. Fit the protective cover on the fuel filter.

10. Remove the plug from the tank connection and fit a new hose on the filler pipe.

Important

The hose to the filler pipe must always be changed when changing the fuel tank. The old hose must not be refitted as there is a risk of it splitting/cracking.


Tightening torques

hose clamps 2,0 Nm (1,4 lbf ft)

11. Fit the filler pipe purge line.

12. Lower the car.