Installing Fuel Tank

Fig 1: Overview Of Degassing Tank And Fuel Tank In Unit

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 2: Overview Of Fuel Tank (Diesel - Single-Pump System)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

The following exploded drawing shows how the fuel tank is attached to the vehicle floor.

Fig 3: Identifying Fuel Tank And Mounting Bolts

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information 

• The top left cover must be fitted before the tank is installed. 
• When installing the tank and rear axle, make sure that cables and lines are not damaged and are in the correct installation position. 
• When introducing the tank into the body, a second person should guide the degassing tank and safeguard it against damage using wire. 

1. Raise the tank with a transmission jack. Make sure to secure the tank with a restraining strap to prevent it from falling.
   Fig 4: Jacking Up Tank

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. With the help of a second worker, place the tank in installation position. A second person should carefully guide the degassing tank.

   Information 

   • Note direction arrow stamped on the restraining straps and install these in the direction of travel. 
3. Attach the lower covers and fit the four restraining straps, which run at right angles to the direction of travel. Make sure that the arrow marking is pointing forward in the direction of travel. Tighten the fastening screws to the specified tightening torque. → Tightening torque: 23 Nm (17 ftlb.) 
4. Secure the fuel filler neck and degassing tank again with a piece of wire -arrow-  .
   Fig 5: Identifying Fuel Filler Neck And Degassing Tank

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Lower the transmission jack and fit the centre restraining strap. The arrow must be pointing forward. Tighten the fastening screws to the specified torque. → Tightening torque: 23 Nm (17 ftlb.) 
   Fig 6: Locating Centre Restraining Strap On Fuel Tank

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Fit the heat protection plate for the exhaust system. If the plate is cracked or damaged, it must be replaced.
   Fig 7: Locating Heat Protection Plate Mounting Bolts

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Fit the underbody panel for the side members at the left and right. → WM 519319 REMOVING AND INSTALLING CENTRE COVER
8. Replace the line bracket and fit it on the longitudinal member. Clip in lines.
   Fig 8: Locating Line Bracket

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Then fit the stone guard on the right side → Fit nuts -arrows-  and tighten to the specified torque. → Tightening torque: 10 Nm (7.5 ftlb.) 
   Fig 9: Locating Stone Guard Mounting Bolts

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Fit all connections on the connection unit. .
    Fig 10: Locating Connection Unit

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.