Removal and Replacement

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 connector (not from the pump armature).
4 Drain the fuel tank as described in the section headed "Emptying the fuel tank."







5 Carefully detach non-return valves with fuel lines from the pump (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, using tool 83 94 702.







9 Detach the hoses from the filler pipe.







10 Detach both handbrake cables at the handbrake lever.
11 Place a pillar jack under the tank.







12 Undo the front bolts securing the strap that holds the tank in place and lower the tank.

To fit
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 torque, hose clips : 2.2 Nm (1.6 lbf ft)

Important
When fitting the filler pipe it is important to replace the old bolt with a new one of plastic. In the event of a collision the plastic screw should give way so that the filler pipe, which is also made of plastic, will not be damaged.

6 Lower the car to the floor.
7 Plug in the connector and reconnect the fuel lines. Smear the O-rings with acidfree vaseline and spray the connectors with Kontakt 61, part No. 30 04 520.

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