Fuel Tank: Service and Repair

Removing And Installing Fuel Tank

Tools







Technical values







Preliminary work

Preliminary work - Carrera 2

DANGER:
Risk of fire from escaping fuel.
- Danger of fatal injury and damage to property.

- Observe basic safety instructions when working on the fuel system.
- Secure working area.







1. Place a warning sign in a clearly visible position in the work area or on the vehicle.
2. Place protective covers on the vehicle.

INFORMATION: Set the steering wheel with the wheels in straight-ahead position. If this is not done, the airbag contact unit will have to be put in centre position after installation of the steering gear.







3. Move steering wheel to centre position (front wheels straight ahead) and lock it with the steering-wheel holder -A-.
4. Remove the two front wheels. Use special tool socket wrench insert P 300 to avoid damage to the rims.
5. Disconnect and remove battery.
6. Remove carrier plate for battery. Unscrew four M8 hexagon collar nuts and remove lid. Check seal for damage and replace it if necessary.
7. Remove fuel level sensor.







8. Empty the fuel tank. Use the fuel transfer unit WE WE1262 to do this. - Emptying and filling the fuel tank.
9. Remove rear part of right front wheel housing liner.
10. Remove filler neck.
11. Remove front and centre underbody cover.







12. Remove sheetmetal support for coolant pipes -2- in the centre tunnel. Unscrew four hexagon-head bolts -1- and unclip plastic support on the coolant pipes and vent line -Arrows-.







13. Remove diagonal braces (marked R = Right, L = Left).







14. Remove longitudinal restraining straps for securing tank and take off cover of fuel tank.







15. Loosen universal joint (steering shaft) at steering gear -Arrow-. To do this, take out the clamping screw and slide the joint upwards.
16. Remove front-axle cross member.










17. Release coolant pipes and secure with a tie-wrap.

Removing fuel tank

Removing fuel tank - Carrera 2

DANGER:
Risk of fire from escaping fuel.
- Danger of fatal injury and damage to property.

- Observe basic safety instructions when working on the fuel system.
- Secure working area.

Overview of the Carrera 2







1. Turn steering gear and move it towards the front (in direction of travel).







2. Unscrew two M8 screws for securing transverse restraining strap to the body at the left and right.

CAUTION:
Damage to fuel-level sensor flange.
- Material damage

- Be particularly careful with the fuel-level sensor flange when levering out or fitting the fuel tank.

INFORMATION: Get another person to help you remove and install the fuel tank.







3. Unclip both clips on the body and get another person to help you lift the fuel tank out of the vehicle. To do this, first tilt the tank towards the right. Pay attention to the tank flange.

Installing fuel tank

INFORMATION: Get another person to help you remove and install the fuel tank.

CAUTION:
Damage to fuel-level sensor flange.
- Material damage

- Be particularly careful with the fuel-level sensor flange when levering out or fitting the fuel tank.

1. Get another person to help you fit the fuel tank into the body. Clip clips into the body take-up points.
2. Place transverse restraining strap at the correct position on the tank and secure with two M8 screws. - Tightening torque: 23 Nm (17 ftlb.)

Subsequent work

Subsequent work - Carrera 2
1. Install front-axle carrier.







2. Secure steering gear to front-axle carrier with two screws and connect universal joint to steering gear.
3. Insert tank guard (bottom) and secure using longitudinal restraining straps. Pay attention to the installation position (left-right). - Tightening torque: 23 Nm (17 ftlb.).
4. Install diagonal braces. - Tightening torque: 100 Nm (74 ftlb.)
5. Fit coolant pipes in centre tunnel. Secure sheetmetal holder. - Tightening torque: 65 Nm (48 ftlb.)
6. Fit plastic holder for coolant pipes. - Tightening torque: 10 Nm (7.5 ftlb.)
7. Install filler neck.
8. Install fuel level sensor.
9. Refuel vehicle - Emptying and filling the fuel tank.
10. Install carrier plate for battery. - Tightening torque: 23 Nm (17 ftlb.).
11. Install battery.
12. Start the vehicle.
13. Check all lines and connections for leaks.
14. Install rear section of front right wheel housing liner.
15. Install underbody panels.
16. Mount front wheels.
17. Remove steering-wheel holder.
18. Perform suspension alignment.
19. Perform a test drive.