Remove Fuel Tank

WARNING: Toxic substances

Danger of poisoning or suffocation
Danger of burns to the eyes and skin
1. → Ventilate the work area well.
2. → Never ingest or inhale.
3. → Read specific information on the Hazard Sheet.
4. → Wear personal protective gear.
5. → Do not smoke, eat or drink in the work area.

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion
1. → Avoid contact with hot parts or sources of ignition.
2. → Use suction to remove ignitable vapours.
3. → Attach warning sign in a clearly visible position.
4. → 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.
5. → Secure collection containers/vessels to prevent them from tipping over.

CAUTION: Risk of damaging fuel lines!

Lines can become kinked or can crack.
1. → Never leave the carbon canister hanging freely on the lines.
2. → A second person must hold the carbon canister during removal.

Information

Soak up escaping fuel using suitable aids.
Dispose of cloths and other items that have absorbed fuel in accordance with the applicable national laws.
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.

Remove heat shields -2 and 4- .

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Centre rear and right heat shields
1. 1.1 Unscrew nuts -1- and remove centre rear heat shield -2- .
2. 1.2 Unscrew nut -3- and remove right heat shield -4- .
Unscrew screws -1- and remove heat shield on fuel tank -2- in -direction of arrow- .

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Heat shield on fuel tank
Fold protective mat -1- aside and open fuel pump cover -2- .

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Fuel pump cover
Disconnect connections on fuel pump -2-

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Fuel pump connections
1. 4.1 Release and disconnect electric plug connections -2 and 3- .
2. 4.2 Lift line bracket -4- out of the guide and set it aside.
3. 4.3 Release fuel lines -5 and 6- , disconnect them and set them aside.
Loosen tank filler neck -2- .

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Tank filler neck
1. 5.1 Screw off the cap.
2. 5.2 Unscrew screws for tank filler neck holder -1- in the wheel housing.
3. 5.3 Pull tank filler neck -2- out of the rubber sleeve -3- .
Support the fuel tank using the > VAS 6832 - Master Gear unit elevating platform or the > VAS 6931 - transmission and engine jack .
Loosen fuel tank -1- from the body.

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Fuel tank on body
1. 7.1 Unscrew screws securing stone guard -2- to the body.
2. 7.2 Unscrew screws securing fuel tank to the body -3- .
3. 7.3 Lower the fuel tank -1- slightly and secure it to prevent it from falling down.
Release and disconnect supply line -1- on the under body at the right.

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Supply line
1. 8.1 If auxiliary heater is installed:
  Loosen auxiliary heater pump -2- from holder -3- and release and disconnect line -4- .
Disconnect carbon canister line -1- .

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Carbon canister line
1. 9.1 Loosen line for carbon canister -1- at the fuel tank -2- and underbody from the holders -Arrows- .
2. 9.2 Release and disconnect line -1- at the carbon canister -3- .