16 11 030 Removing and installing or replacing fuel tank (gasoline)

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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!

Avoid skin contact (wear gloves)!

After installation of fuel tank/prior to first engine start-up:

Fill fuel tank with min. 5 l fuel.
Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection.
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: Screws And Cover

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Left sensor unit:

Disconnect plug connection (1).

Press grey ring (2) towards sensor unit and pull out fuel feed line (3).

Fig 2: Disconnect Plug Connection And Press Grey Ring Toward Sensor Unit

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USA national version:

Disconnect plug connection (1).

Unlock and detach vent lines (2).

If necessary, remove fuel line for independent heating.

Fig 3: Identifying Plug Connection And Vent Lines

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ECE national-market version:

Right sensor unit: Disconnect plug connection (1).

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

Installation:

Make sure quick-release fasteners engage correctly.

Fig 4: Identifying Plug Connection And Vent Line

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IMPORTANT:

There may still be residual amounts of fuel in the tank.

Catch and dispose of escaping fuel.

Release hose clamp (1) and detach fuel filler hose from fuel filler pipe.

If necessary, draw off residual amount of fuel via filler hose.

Installation:

Tightening torque: see 1AZ in 16 12 FUEL DELIVERY .

Fig 5: Identifying Hose Clamp

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

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

Fig 6: Identifying Quick-Release Fastener, Vent Line And Holder

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Heavily support the fuel tank.

Fig 7: Identifying Fuel Tank With Support

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Unfasten nut.

Installation:

Replace self-locking nut.

Tightening torque: see 1AZ in 16 11 FUEL TANK AND MOUNTING PARTS .

Fig 8: Locating Self-Locking Nut

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

Carefully lower fuel tank.

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

Installation:

Tightening torque: see 2AZ in 16 11 FUEL TANK AND MOUNTING PARTS .

Fig 9: Locating Straps Screws

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Installation:

Note rubber mount with spacer bush.

Wide collar on spacer bush points to screw head.

Fig 10: Locating Spacer Bush

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

Modify vent line (1)
Modify RIGHT SENSOR UNIT (2)
Modify LEFT SENSOR UNIT (3)

Fig 11: Identifying Vent Line, Right And Left Sensor Unit

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