Removal and Replacement
Fuel tank, replacing
Special tools:
999 7057 Counterhold 999 7057 Counterhold
Note! Since 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.
Preparation
Drain the fuel tank. See: Fuel tank, draining Procedures.
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.
Remove 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:
- 2 screws for the cable clips
- 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! Suspend catalytic converter to prevent damaging the flex gaiter.
Removing the propeller shaft
Mark up the position of the joint on the drive flange on the final drive and at the center bearing. Remove the screws for the joints. Use counterhold 999 7057 Counterhold 999 7057 Counterhold.
Remove the rear section of the propeller shaft.
Lowering the rear suspension
Place the mobile jack: 999 5972 FIXTURE 999 5972 Fixture with plate: 999 5972 FIXTURE 999 5972 Fixture under the rear end.
Raise to light contact.
Remove the following on both sides:
- the 2 screws for the mounting bracket
- the mounting screw for the sub frame bushing.
Disconnect the brake pipe on both sides from the plastic clips on the bracket.
Lower the rear suspension carefully.
Removing the fuel tank
Install the 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 securing strap.
Remove:
- the clamp for the fuel filler pipe
- the clamp for the bleed pipe.
Lower the lifting table to access the plastic pipes on top of the tank.
Remove:
- the plastic pipe
- The ABS cable harness from the clips on both sides of the fuel tank.
Remove the tank.
Transferring components
Removing the splash guard pipe
Remove the splash guard pipe and 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! Watch out for fuel splashes.
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 screws (x 2)
- the tank retaining strap
- the screws (x 2)
- the heat deflector plate.
Installation
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Removal and Replacement.
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. ( 10 Nm).
Installing the level sensor
Install the sealing ring.
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 in the front part of the fuel tank.
Install on the left-hand side:
- sealing cover
- the ejector
- the connectors
- level sensor ( 60 Nm) (Use special tool 999 5720 Wrench 999 5720 Wrench ).
Note! Ensure that the arrow ends up directly opposite the marking on the tank.
Install on the right-hand side:
- level sensor ( 60 Nm) (Use special tool 999 5720 Wrench 999 5720 Wrench ).
Ensure that the arrow ends up directly 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.
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 filler pipe and breather pipe slide into position while raising the fuel tank.
Install the 4 screws for the mounting for the securing strap. Tighten to 24 Nm.
Remove the lifting table.
Install:
- the clamp for the fuel filler pipe
- the clamp for the bleed pipe
- the upper plastic pipe in the quick-release connector for the carbon filter container.
Installing the rear suspension
Place the mobile jack 999 5972 FIXTURE 999 5972 Fixture with plate 999 5972 FIXTURE 999 5972 Fixture under the rear end.
Carefully raise the rear suspension.
Note! Ensure that no cable harnesses or brake pipes are trapped while raising.
Install on both sides:
- the 2 screws for the mounting bracket. Tighten to 80 Nm
- the screw for the sub frame mounting. Tighten to 80 Nm
- the brake pipe in the plastic clip on the bracket.
Installing the brakes
Install:
- the parking brake cable along the heat shields
- the screws in the center and front mountings for the heat shield.
Install:
- the parking brake cables on the wheel units
- the parking brake cable mountings in the sub-frame. ( 25 Nm )
- the mounting for the parking brake cable 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 with lubricant 1161580 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. Tighten to 10 Nm
- the brake caliper. Use new screws. Tighten to 60 Nm.
Note! Activate the parking brake adjuster according to Parking brake self-adjustment, resetting Parking Brake Self-Adjustment, Resetting.
Installing the propeller shaft
Position the propeller shaft as marked previously.
Install new screws for the joints. Use counterhold 999 7057 Counterhold 999 7057 Counterhold.
For tightening torques, see Tightening torque Tightening Torque.
Installing the exhaust system
Install the exhaust system. Use a new flange gasket. Tighten the screws. Tighten to 25 Nm.
Finishing
Finishing
Install the cover over the level sensor. Tighten the nuts. Refer to: Fuel tank, draining Procedures
Connect the wiring and the connectors.
Remove the block from under the seat frame
Install on both sides:
- the wiring in the slots on the rubber seal.
- the cover over the level sensors and tighten with 6 Nm
- both polystirene 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).