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Fuel tank

Fuel tank

Warning

Replacement 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.


To remove



1. Raise the rear seat cushion and fold back the carpet.

2. Remove the fuel pump cover.

3. Unplug the upper connector.

Important

The connector on the pump must not be removed.


4. Drain the fuel from the tank. See

5. Carefully detach the non-return valves with fuel lines (move the yellow hooks aside, using a screwdriver). The non-return valves are secured to the pump by means of clips. The white one represents the pressure side and is marked "Pressure" on the pump. The black one represents the return side and is marked "Return" on the pump. Move the non-return valves aside and fasten them under the metal fold.


6. Raise the car.

7. Remove the rear exhaust pipe section.

8. Separate the purge pipe with the tool, part no. 83 95 261.


9. Detach the hoses to the filler pipe by undoing the filler pipe plastic bolt.


10. Detach both handbrake cables at the handbrake lever.


11. Place a pillar jack under the tank.

12. Undo the front screws on the straps securing the tank and lower it.



To fit

Note

Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting them.



1. Carefully jack up the tank.

2. Fit the handbrake cables.

3. Fit the straps.

4. Fit the purge pipe.

5. Fit the filler pipe.

Tightening torques:

Plastic bolt 1.5 Nm (1.1 lbf ft)

Hose clips 4 Nm (2.9 lbf ft)

Important

When fitting the filler pipe it is important to replace the rubber hoses between the filler pipe and the fuel tank. There is a risk of cracks forming on the hoses after repeated tightening of the hose clips and this can lead to fuel leakage.

It is also important to replace the old plastic bolt by a new bolt of plastic. In the event of a collision, the plastic bolt will break thus avoiding any damage to the filler pipe which is also made of plastic.


6. Lower the car to the floor.

7. Plug in the connector and connect the fuel lines. Apply acid-free vaseline on the O-rings.

Important

Inspect O-rings when fitting the fuel lines and change them as necessary.