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Fuel tank, 4WD

Fuel tank, 4WD

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. Reduce the fuel pressure by removing fuse 2 when the engine is running (fuse 2 is in the electrical box in front of the battery). When the engine has stopped, turn the ignition key to LOCK and refit the fuse.

2. Drain the fuel tank. Refer to Draining the fuel tank, 4WD .

3. Raise the car.

4. Remove the exhaust system. Refer to Exhaust system assembly, 4WD .

5. Remove Propeller shaft

6. Remove the protective covers (A).


7. Place a receptacle under the tank.

8. Detach the fuel tank fuel line (A) and the bleeder line (B). Plug the lines with suitable plugs.


9. Unplug fuel tank connector (C) and remove it from its bracket.

10. Remove the filler pipe bolt (A), the hose clip (B) and the bleeder hose quick coupling (C). Detach the filler pipe hose from the tank.


11. Secure the rear final drive with 83 95 212 Strap .


12. Lower the torque clutch approx. 10 mm by slackening the bolts (A).

13. Place a column jack under the tank, remove the tank strap bolts (A) and remove the tank. Take care when removing the tank and make sure none of the components or connections are damaged.



To fit


1. Replace the connecting hose between the tank and the filler pipe.

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

3. Fit the tank strap bolts (A) and lower the column jack.

Tightening torque 25 Nm (18 lbf ft)

4. Plug in the fuel tank connector (C) and fit it into its bracket.


5. Remove the plugs and attach the fuel line (A) and bleeder line (B).

6. Attach the filler pipe hose and tighten the hose clip (C). Fit the bleeder hose quick coupling (C) and fit the bolt (A).


7. Tighten the rear final drive bolts (A). Remove the strap.

Tightening torque: 90 Nm + 90 degrees


8. Fit the protective covers (A).


9. Fit the propeller shaft

10. Fit the exhaust system. Refer to Exhaust system assembly, 4WD .

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

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

13. Connect the diagnostic tool and erase any diagnostic trouble codes.