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Fuel tank

Fuel tank

Warning

Changing the fuel tank involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with the 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 close at hand! Beware of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.

• No smoking anywhere in the vicinity.


Dismantling



1. Drain the fuel from the tank, refer to Draining the fuel tank .

2. Place the car on a lift. Make sure the rear right-hand lift-arm pad is placed as far out as possible to facilitate the work.

3. Raise the car.

4. Detach the rubber hoses and breather line from the tank and plug the tank. Use special tool no. 83 94 777.

5. Remove the plastic cover on the fuel filter, 2 screws, and undo the clamp securing the fuel filter.

6. Support the tank with a column lift and then undo the nuts on the tank straps. Unhook the straps.

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


Important

Detach the fuel lines from the snap fasteners on the tank and body without bending or breaking them.


8. Unplug the electrical connector to the fuel pump.

9. Detach the delivery and return lines from the fuel pump.

10. Lower the tank to working height.


To fit



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

2. Connect the delivery and return lines from the fuel pump.

Important

Inspect the O-rings before fitting them on the fuel lines. Replace them if necessary.


3. Plug in the electric connector to the fuel pump.

4. Lift the tank into position.

Important

Mount the fuel lines in the snap fasteners on the tank and body.



5. Hook on the straps and fit the nuts.

6. Fit the clamp for the fuel filter.

Fit the plastic cover.

7. Remove the plugs and fit new rubber hoses to the tank. Connect the breather line.

Tightening torques

Hose clips: 2.2 Nm (2 lbf ft)

Important

The hoses to the filler pipe must always be replaced with new ones after removing the fuel tank. They must not be refitted as there is risk of them cracking.


8. Lower the car to the floor.