Fuel Tank, Replacing

Replacing the fuel tank

Removal

Draining the fuel system
To drain the fuel from the system, see Draining the fuel system.

Draining the tank
If the fuel tank is more than half full, drain the fuel tank according to Draining the fuel tank.

In the passenger compartment

Remove







- the backrest according to Backrest.
- the insulation panel.







- Remove the covers over the fuel level sensors.
- Disconnect the 2 connectors on the left and 2-3 on the right-hand side. Let them follow the fuel tank down.

Rear section of the exhaust pipe
Raise the car

Remove







- the rear section of the exhaust pipe. Support the front section of the exhaust pipe so as not to put strain on the exhaust manifold.

Heat deflector plate







- Remove the left rear wheel.
- Remove the rear plastic nut from the plastic fender liner.
- Drill out the two blind rivets holding the heat deflector plate at the rear sub-frame mounting and the third rivet on the rear bracket for the exhaust system. Use a 5 mm drill bit
- Remove the plastic nuts and the heat deflector plate.

Exposing the fuel tank

Remove







- the plastic pipe with the largest connection to the carbon filter container by pressing towards the container, pressing the two catches and pulling off. Position the pipe forwards against the fuel tank.
- the plastic pipe between the canister purge (CP) valve and the carbon filter container from the clip on the fuel tank.
- the ABS wiring from the fuel tank.
- the bracket for the fuel filter
- the brake cable from the left rear brake according to Replacing brake cables.
- the screws from the heat shield at the front of the fuel tank. Position the brake cables in front of the heat shield.
- the hose clamps, fuel filler pipe and the shut-off pipe at the fuel tank.

Lowering the fuel tank

Apply the mobile jack with fixture 999 5972 under the fuel tank.

Remove







- the tank retaining straps and lower the tank slightly
- the hoses from the tank unit.

Check that the lines and wiring are unimpeded during the rest of the lowering.

Draining fuel tank
Drain the fuel from the fuel tank according to Draining the fuel tank.

Transferring components

Transfer
- the right level sensor and pump according to Level sensor, fuel tank, right-hand/fuel tank, replacing.
- the left level sensor according to Replacing the level sensor for the left-hand fuel tank.
- the fuel tank pressure sensor, see Pressure sensor, fuel tank, replacing (certain markets only).
- the hoses for the fuel filler pipe and breather pipe.
- the fuel filler extension in the fuel tank.
- the heat shield under the fuel tank.
- the clip for the brake cable.
- the tank straps.

Installation

Fuel tank







- Lift up the fuel tank
- Install the hoses on the fuel tank unit. Ensure that no lines or wiring are trapped.
- Position the wiring to be routed into the passenger compartment uppermost.
- Install the fuel filler pipe and the bleed pipe. Use new screw clips.

NOTE: Install the screw clips so that they can be easily tightened.

- Tighten the screws for the tank retaining straps. Tighten to 25 Nm.
- Remove the mobile jack.

Install
- the fuel filter with the bracket Tighten to 25 Nm.
- The ABS wiring in the clips on the fuel tank.
- the brake cables behind the heat shield at the front edge of the fuel tank and in the clips. Screw the heat shield into place.
- the brake cable at the left rear brake according to Replacing brake cables
- the plastic pipe between the canister purge (CP) valve and the carbon filter container in the clip on the fuel tank.
- the plastic pipe with the largest connection to the carbon filter container. A "click" must be heard.

Heat deflector plate







- Position the heat deflector plate and install the plastic nuts.
- Install the pop rivets, one at the bracket for the exhaust system and two on the rear mounting for the sub-frame.
- Install the left rear wheel.

The rear section of the exhaust pipe







- Install the exhaust system. Tighten the screws. Tighten to 25 Nm.

The passenger compartment

Install







- The 2-3 connectors on the right and the 2 connectors on the left.
- the covers over the level sensors. Check that the gasket is correctly positioned.
- the insulation panel.
- the backrest according to Backrest.