Removing Fuel Tank

WARNING: Toxic substances

Danger of poisoning or suffocation
Danger of burns to the eyes and skin
→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Wear personal protective gear.

→ Do not smoke, eat or drink in the work area.

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion
→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

→ Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.

→ Secure collection containers/vessels to prevent them from tipping over.

CAUTION: Risk of damaging fuel lines!

Lines can become kinked or can crack.
→ Never leave the carbon canister hanging freely on the lines.

→ A second person must hold the carbon canister during removal.

Information

Escaping fuel must be soaked up using suitable binding material.
The fuel system must be depressurised before starting work on it.
Only work on the fuel system in well-ventilated rooms.
Any seals that were removed must always be replaced.
Never use sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.

Information

For safety reasons, the fuel tank should only be removed and installed when empty.

> 200317 DRAINING AND FILLING FUEL

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Component overview of degassing tank and fuel tank in the unit

Fig 1: Fuel Tank Components Location (Diesel - Single-Pump System)

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Component overview of fuel tank (diesel - single-pump system)

1	Fuel filler neck
2	Fuel tank
3	Left cap
4	Locking ring
5	Left fuel level sensor
6	Sucking jet pump, left
7	Protective cover
8	Restraining strap
9	Fastening screw
10	Protective cover
11	Left sucking jet pump (on tank floor)
12	Fuel pump (delivery unit)
13	Right fuel level sensor
14	Protective cover
15	Right cap

Open the filler flap and unscrew the fastening screw on the hook.
Loosen and remove the filler flap. To do this, insert a thin screwdriver through the four indents -illustration- and release the filler flap.

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Releasing filler flap
Remove the rubber sleeve around the fuel filler neck, unscrew the two fastening screws and remove the ground cable.

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Tank filler neck
Remove the cover under the rear seats. To do this, fold up the carpet at the markings and screw off four fastening nuts > Fuel tank openings in body .

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Fuel tank openings in body

Left opening

5.1 Release and disconnect cable plug

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Cable at left opening

Right opening
1. 6.1 Release and disconnect two cable plugs -1 and 2- .
2. 6.2 Release and disconnect the fuel line -3- at the tank.
  Information
  
  Lower the fuel tank slightly in order to release the fuel line.
3. 6.3 Remove the fuel line -4- from the holder and release and disconnect it.
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Opening on right side
Disconnect cable plug for fuel pump control unit.

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Connector on fuel pump control unit
Remove cover in wheel housing at the rear right. To do this, unscrew three fastening screws -arrow- and pull off the cable holder.

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Stone guard
Unscrew fastening screws on the filler neck and degassing tank -3- .

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Filler neck
Remove the line bracket under the stone guard by pressing in the centre plug -arrow- .

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Line bracket
Release and disconnect two lines -1 and 2- on the active carbon filter.

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Filler neck
Loosen the tank attachment band, which runs in direction of travel -arrows- . Support the tank using the > VAS 6832 - Master Gear unit elevating platform.

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Tank attachment band

Get another worker to help you to loosen and remove the remaining restraining straps. Slowly lower the fuel tank using the > VAS 6832 - Master Gear unit elevating platform. Also guide out the degassing tank in the right wheel housing.

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Fuel tank mount

No.	Designation	Qty.	Removal	Installation
	Fuel tank	1	Do not damage fuel tank and connected lines. Lines cannot be replaced individually.	Do not damage fuel tank and connected lines. Lines cannot be replaced individually.
-2-	Restraining strap, front left	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.
-3-	Fastening screw, M8 x 25	10
-4-	Plastic covers, left	2
-5-	Plastic cover, right	1
-6-	Restraining strap, rear right	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.
-7-	Restraining strap, front right	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.
-8-	Restraining strap, centre	1		The direction of travel arrow must be pointing forward.
-9-	Restraining strap, rear left	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.

Slowly lower the fuel tank using the transmission jack and carefully guide in the degassing tank in the right wheel housing.

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Tank on jack