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

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Recycling

Fuel escapes when fuel lines are detached. Have a suitable collecting vessel ready.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

IMPORTANT: Ensure adequate ventilation in the workbay!
Avoid skin contact (wear gloves)!
After installation of fuel tank/prior to first engine start-up:

Check earth 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 at least 5 liters of fuel.

Necessary preliminary work:

Draw off FUEL from fuel tank
Remove rear seat bench
Remove rear right wheel arch panel
Remove PROPELLER SHAFT
Remove COMPRESSION STRUT on left and right

Fold both floor trims (1) to the side.

Unfasten screws (2).

Remove cover for sensor opening (3).

Fig 1: Identifying Both Floor Trims And Screws

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Disconnect plug connection (1).

Disconnect fuel line (2).

If necessary, disconnect fuel line for auxiliary heating.

Installation note:

Check gasket (3), replace if necessary.

Fig 2: Identifying Fuel Line And Plug Connection

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Release plastic nut (1).

Installation note:

Check plastic nut (1), replace if necessary.

Tightening torque 16 12 2AZ .

Unclip line clip (2).

Release snap fastener (3).

Fig 3: Identifying Plastic Nut And Line Clip

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IMPORTANT: There may be residual amounts of fuel in the fuel tank.
Catch escaping fuel in a suitable container.

Unfasten hose clamp (1).

Installation note:

Check hose clamp, replace if necessary.

Tightening torque 16 12 1AZ .

Remove fuel filler pipe from fuel tank.

Fig 4: Identifying Hose Clamp

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Unscrew nuts (1).

Installation note:

Tightening torque 16 11 1AZ .

Fig 5: Identifying Fuel Filler Pipe And Nuts

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IMPORTANT: Secure fuel tank against slipping and falling out.

Heavily support the fuel tank.

Fig 6: Supporting Fuel Tank

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Release screws (1).

Installation note:

Tightening torque 16 11 2AZ .

Lower fuel tank.

Fig 7: Identifying Lower Fuel Tank And Screws

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If necessary, disconnect fuel line for auxiliary heating.

Feed out tank ventilation line through body opening.

Remove fuel tank.

Replacement:

Convert FUEL PUMP
Modify fuel level sensor