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Home >> Porsche >> 2016 >> Cayman GTS, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 78 (20 - Fuel Supply, Control) >> WM 201019 Removing And Installing Fuel Tank >> Removing Fuel Tank

Removing Fuel Tank

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Degassing Tank And Fuel Tank Components
G09409782Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fig 2: Identifying Fuel Tank Component Overview (Diesel - Single-Pump System)
G09409783Courtesy 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
  1. Open the filler flap.
  2. Screw the tank cap down. Then remove the rubber sleeve around the tank filler neck, loosen the two fastening screws (M6 x 20) and pull off the ground cable.
    Fig 3: Removing Rubber Sleeve Around Tank Filler Neck
    G09409784Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Pull the fuel filler neck and degassing tank out of the wheel well and secure with a piece of wire -arrow-  (figure shows degassing tank with carbon canister).
    Fig 4: Locating Degassing Tank Wire
    G09409785Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Then, loosen the stone guard on the right side. Remove screws -2-  .
    Fig 5: Locating Stone Guard Mounting Bolts
    G09409786Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Remove the line bracket under the stone guard by pressing on the centre plug -arrow-  . Replace the line bracket.
    Fig 6: Locating Bracket Line
    G09409787Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Remove the centre underbody cover at the left and right on the longitudinal side members. → Removing centre cover
  7. Remove rear heat protection plate. To do so, loosen the three speed nuts and two screws.
    Fig 7: Locating Heat Protection Plate Mounting Bolts
    G09409788Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Undo the tank attachment band, which runs in the direction of travel -arrows-  . Then, position a transmission jack under the tank and secure the tank from falling using a belt. When doing so, make sure that the fuel lines are not damaged.
    Fig 8: Locating Tank Attachment Band
    G09409789Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

    Fig 9: Identifying Fuel Tank And Mounting Bolts
    G09409790Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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.
    CAUTION: Risk of damaging to fuel lines!
    • Lines can become kinked or can crack.

    → Never leave carbon canister hanging freely on the lines.

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

  9. Get another worker to help you to loosen and remove the remaining restraining straps. Slowly lower the tank with the transmission jack. Also guide the degassing tank in the right wheel housing.
    Fig 10: Jacking Up Tank
    G09409791Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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