Removal and Replacement
Fuel tank, replacing
Special tools:
999 5720 Wrench 999 5720 Wrench
Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.
Removal
Preparatory work
Drain the fuel tank. See Fuel tank, draining Fuel Tank Draining.
Block the parking brake pedal in the neutral position. See Parking brake self-adjustment, resetting Parking Brake Self-Adjustment, Resetting.
Remove the following on both sides:
- the wheel
- the brake caliper. See Brake calipers rear, replacing Brake Calipers Rear, Replacing
- the brake discs. See Brake disc rear, replacing Brake Disc Rear, Replacing.
Detach the tension spring. Remove the expander. Lift the brake shoe slightly. Grip the expander. Pull the expander outwards.
Unhook the expander from the metal bracket.
Remove the following on both sides:
- the guide sleeve for the cable sleeve. Apply a screwdriver between the guide sleeve lug and wheel arch. Pry apart slightly to remove the sleeve.
Remove the parking brake cable from the tie rod and the sub-frame on both sides.
Remove:
- the 2 screws for the cable clips
- the 2 screws for the front mounting for the heat deflector plate.
Fold out the cables from the heat deflector plate. Hang the cables up at the front of the car.
Remove the exhaust system from the three-way catalytic converter (TWC) and backwards.
Note! Hang up the three-way catalytic converter (TWC) to prevent damaging the flex boot.
Removing the fuel tank
Install a lifting table under the fuel tank.
Remove:
- the upper quick-release connector plastic pipe on the carbon filter container
- the 4 screws for the mounting for the fuel tank straps in the car.
Remove:
- the hose clamp for the fuel filler pipe
- the hose clamp for the bleed pipe.
Lower the lifting table to access the plastic pipes on top of the tank.
Remove:
- the plastic pipes
- The ABS cable harness from the clips on both sides of the fuel tank.
Remove the fuel tank.
Transferring components
Removing the splash guard pipe
Remove the splash guard pipe and the bleed pipe. Pull straight out.
Removing the level sensor
Lift the left level sensor.
Remove:
- the connector
- the ejector.
Grip the right-hand level sensor/pump. Pinch the float to hold it in its lowest position.
Carefully and slowly pull up the holder. Carefully work the holder out.
Pull the hoses and the wiring out of the tank.
Note! Take care with the fuel tank.
Note! It is extremely important that the float arm is not broken or bent.
Removing the tank retaining strap and heat deflector plate
Remove:
- the 2 screws
- the tank retaining strap
- the 2 screws
- the heat deflector plate.
Installing the tank retaining strap and heat deflector plate
Install:
- the heat deflector plate
- the 2 screws. Tighten to 5 Nm
- the tank retaining strap
- the 2 screws. Tighten to 10 Nm.
Installing the level sensor
Lubricate the sealing ring using petroleum jelly and install it.
Route the cable harness/hoses from the right level sensor to the left side of the tank as illustrated.
Hint: Use a welding rod bent into a curve with a hook at one end to pull the cable harness/hoses to the correct position.
Note! It is very important for installing the level sensor that the cable harness/hoses are routed into the front section of the fuel tank.
Install on the left-hand side:
- the sealing ring, lubricate it first with petroleum jelly
- the ejector
- the connectors
- the level sensor. Use wrench999 5720 Wrench 999 5720 Wrench and tighten. See Tightening torque Tightening Torque.
Note! Ensure that the arrow is opposite the marking on the tank.
Install on the right-hand side:
- the level sensor. Use wrench999 5720 Wrench 999 5720 Wrench and tighten. See Tightening torque Tightening Torque.
Ensure that the arrow is opposite the marking on the tank.
Installing the splash guard pipe
Install the splash guard pipe.
Note! Ensure that the locating pin is correctly positioned for the groove in the tank.
Installation
Installing the fuel tank
Place the fuel tank on the lifting table.
Raise the lifting table to install the plastic hoses on the right-hand level sensor and in the grooves in the tank.
Secure the hoses in place using silver tape.
Install the ABS cable harnesses in the clips on both sides of the tank.
Align the fuel filler pipe and the bleed pipe.
Insert the cable harnesses for the level sensor and the fuel tank pressure sensor through the inspection holes in the floor.
Raise the fuel tank to the installation position.
Note! Ensure that the fuel filler pipe and bleed pipe slide into position whilst raising the fuel tank.
Install the 4 screws for mounting the fuel tank straps in the vehicle. Tighten to 24 Nm.
Remove the lifting table.
Install:
- the hose clamp for the fuel filler pipe
- the hose clamp for the bleed pipe
- the upper quick-release connector plastic pipe on the carbon filter container.
Installing the brakes
Install:
- the parking brake cables along the heat shield
- the screws in the center and front mountings for the heat shield.
Install:
- the parking brake cables on the wheel unit
- the mountings for the parking brake cables in the sub-frame. Tighten to 25 Nm
- the plastic clips for the parking brake cables on the tie rods.
Press the guide sleeves for the parking brake cables into place on the wheel units.
Note! Lubricate the O-rings on the guide sleeves. Use lubricant 116 1580 or silicon grease.
Install:
- the expander on the cable. Press the mounting together to lock the cable in the expander
- the expander between the brake shoes
- the return spring.
Check the function.
Install:
- the brake disc and the locating pin
- the brake caliper. Use new screws.
Tighten. See Tightening torque Tightening Torque.
Note! Activate the parking brake adjuster. See Parking brake self-adjustment, resetting Parking Brake Self-Adjustment, Resetting.
Installing the exhaust system
Install the exhaust system. Use a new flange gasket. Tighten. See Tightening torque Tightening Torque.
Finishing
Install the cover over the level sensor. Tighten the nuts.
Connect the wiring and the connectors.
Remove the block from under the seat frame.
Install:
- the 6 screws for the seat frame. Tighten to 50 Nm
- the 2 screws for the seat frame. Tighten to 24 Nm
- both polystyrene blocks
- the ventilation pipe.
Fold the carpet down.
Install:
- the center rear seat. See Upholstery backrest cushion center (second row), replacing Upholstery Backrest Cushion Center (Second Row), Replacing
- the outer rear seat. See Upholstery backrest cushion outer (second row) Upholstery Backrest Cushion Outer (Second Row).