Remove Fuel Tank

WARNING: Flammable 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.

WARNING: Caustic fluids

Danger of chemical burns
→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ Avoid contact with caustic fluid.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Information

Despite the fact that the coolant has been drained, residual amounts of coolant can still emerge at the joints during removal. Have sufficient collecting containers and cloths to hand.

Overview of fuel tank components

Fig 1: Overview Of Fuel Tank Components Location

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Overview of parts in all-wheel fuel tank

1	Fuel tank
2	Fuel pump
3	Fuel filter
4	Union nut
5	Flange
6	Fuel level sensor
7	Sucking jet pump
8	Sealing ring on flange
9	Carbon canister
10	Leakage diagnosis unit
11	Tank vent line
12	Retaining strap
13	Fastening screw for transverse retaining strap
14	Fuel tank cap
15	Fastening screws for filler neck holder
16	Filler neck
17	Protective pan for fuel tank
18	Retaining straps for fuel tank

Unscrew screws -1- on the holder.

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Filler neck mounting
Loosen filler neck.
Open clamp for filler neck -A- .

Pull filler neck off the connection at the fuel tank -B- .

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Removing filler neck
Release -a- and disconnect -arrow- plug connections on fuel level sensor.
Not necessary if the flange has already been removed in order to extract fuel.

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Disconnecting plug connections

Information

Watch out for emerging fuel when disconnecting fuel lines. Place a clean cloth on the connection point, then loosen the connection.
Release the tank vent line at the fuel tank -A- and pull it off -B- .

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Loosening fuel line
Disconnect fuel line.
Open lock -A- (if fitted).

Release -B- and pull off -C- fuel line.

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Loosening fuel line
Unclip lines -1- at the fuel tank.

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Unclipping lines
Remove left coolant pipe -1- .
Unscrew screw -2- .

Loosen coolant pipe -1- from holder -3- .

Loosen circlips -4- .

Release and disconnect electric connector -5- .

Pull off coolant pipe -1- and catch escaping coolant.

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Front left coolant pipe
Remove right coolant pipe -1- .
Unscrew screw -2- .

Loosen coolant pipe -1- from holder -3- .

Loosen circlips -4- .

Pull off coolant pipe -1- and catch escaping coolant.

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Front right coolant pipe

Information

Get another person to help you to remove and install the fuel tank.
Remove fuel tank.
Unscrew two screws (M8 x 40) -1- .

Unclip clips -2- and get another person to help you lift the fuel tank out of the vehicle.

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Fuel tank mount