1611030 Removing and installing or replacing fuel tank (diesel)

Recycling

Fuel escapes when fuel lines are detached.

Have a suitable collecting container ready.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

IMPORTANT: Ensure adequate ventilation in the place of work!
After installation of fuel tank/prior to first engine start-up:

Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection.
Fill fuel tank with min. 5 l fuel.
Check TRANSFER FUNCTION OF SUCTION JET PUMP .

Necessary preliminary tasks

DRAW OFF FUEL FROM FUEL TANK
Remove REAR SEAT BENCH
Remove GUIDE TUBE FOR HANDBRAKE CABLES
Remove right WHEEL ARCH TRIM
Remove REAR LEFT AND RIGHT UNDERBODY PANELLING
Remove left and right UNDERBODY COVER

Release screws (1) and remove cover (2) from left and right sides of fuel tank.

Fig 1: Identifying Screws And Cover

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Left sensor unit:

Disconnect plug connection (1).

Unlock quick-release fastener (2) and detach line towards front.

Unlock quick-release fastener (3) and detach line towards top.

Installation:

Make sure quick-release fasteners engage correctly.

Fig 2: Identifying Plug Connection And Quick Release Fastener

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Right sensor unit:

Disconnect plug connection (1).

Fig 3: Identifying Plug Connection

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Release hose clamp (1) and detach fuel filler hose (2).

Installation:

Tightening torque, see 16 12 1AZ in 16 FUEL SUPPLY .

Fig 4: Identifying Hose Clamp And Fuel Filter Hose

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Unlock quick-release fastener (1) and detach vent line (2).

Detach vent line (2) from holder (3).

Fig 5: Identifying Quick Release Fastener, Vent Line And Holder

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Heavily support the fuel tank.

Fig 6: Identifying Fuel Tank With Support

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Unfasten nut.

Installation:

Replace self-locking nut.

Tightening torque, see 16 11 1AZ in 16 FUEL SUPPLY .

Fig 7: Replacing Self Locking Nut

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Release screws for tightening straps on left and right and remove tightening straps.

IMPORTANT: Carefully feed the vent line through the body when lowering the fuel tank.

Carefully lower fuel tank.

Installation:

Tightening torque, see 16 11 2AZ in 16 FUEL SUPPLY .

Fig 8: Removing Tightening Straps

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Installation

Note rubber mount with spacer bush.

Wide collar on spacer bush points to screw head.

Fig 9: Identifying Rubber Mount With Spacer Bush

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The following components must be modified when the fuel tank is replaced:

Vent line (1)
RIGHT SENSOR UNIT (2)
LEFT SENSOR UNIT (3)

Fig 10: Identifying Vent Line And Sensor Units
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