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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.

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


Important

Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.


To remove


1. Drain the fuel tank. Refer to Draining the fuel tank .

2. Raise the car.

3. Remove the exhaust system by removing the three nuts from the catalytic converter and removing the rubber mountings.

4. Unplug and remove the connector from the fuel tank.


5. Place a receptacle under the tank.

6. Remove the fuel lines from the fuel tank. Plug the lines with suitable plugs. Cars with auxiliary heater: Disconnect the fuel line to the auxiliary heater and plug the line with a suitable plug. Leave the pump in place in its bracket on the fuel tank.

7. Remove the hose clip and bend aside the filler pipe hose.


8. Place a column lift under the tank for support and remove the bolts holding the tank straps.

9. Lower the column lift and remove the fuel tank.

Note

Angle the fuel tank slightly so that it clears the rear anti-roll bar.



To fit


1. Place the fuel tank on a column lift and carefully lift it into place.

2. Fit the tank straps and lower the column lift.

Tightening torque 25 Nm (18 lbf ft)


3. Fit the filler pipe hose and tighten the hose clip.

4. Remove the plugs and fit the fuel lines.


5. Plug in the connector to the fuel tank and fit it into its bracket.

6. Fit the exhaust system using a new gasket, new nuts and the rubber mountings. Apply 30 20 971 Screw-thread paste to the studs. Tighten the joint with the catalytic converter.

Tightening torque 25 Nm (18.5 lbf ft) .

7. Lower the car and fill the tank with fuel.

8. Bleed the fuel system. Refer to Bleeding the fuel lines .

Cars with auxiliary heater: Start the heater to bleed the fuel lines. If the fuel heater does not start after a number of attempts, start it with the diagnostic tool.

9. Start the engine to check its function and for any fuel leaks.