Removal and Replacement
WM 201019 Removing and installing fuel tank
Tools
Technical values
Preliminary work
WARNING
Highly inflammable 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.
DANGER
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.
1. Raise the vehicle at the prescribed jacking points.
-> 4X00IN01 Lifting the vehicle Service and Repair.
2. Observe safety instructions when working on the fuel system.
2.1. Display a warning sign in a clearly visible position in the work area or attach to the vehicle.
Warning sign for naked flames
3. Place protective covers on the vehicle.
Information
- Use only steering wheel holders -A- that do not project into the area of the airbag unit -B-.
- If necessary, shorten guiding rod at the top -arrow-.
Steering-wheel holder (example shown)
4. Move steering wheel into centre position.
Use the steering-wheel holder -A- to secure the steering wheel in the centre position.
Steering-wheel holder
5. Remove front wheels.
Use special tool socket-wrench insert P 300 to avoid damaging the rims.
-> 44051900 Removing and installing wheel - section on "Removing" Removal and Replacement.
6. Disconnect ground cable on the battery.
-> 2706IN Work instructions after disconnecting the battery External Power Connection, Jump Lead Starting.
7. Remove fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Removing" Service and Repair.
8. Drain the fuel tank.
Fuel transfer unit WE WE1262 should be used.
-> 2010EN Emptying and filling fuel tank.
9. Remove rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair.
10. Remove filler neck.
-> 200719 Removing and installing filler neck - section on "Removing" Service and Repair.
11. Remove underbody panelling.
-> 519419 Removing and installing rear cover - Removing 519419 Removing and Installing Cover for Rear Underbody.
-> 519320 Removing and installing centre cover - Removing 519319 Removing and installing Cover For Centre Underbody.
-> 519219 Removing and installing front cover - section on "Removing" 519219 Removing and installing Cover For Front Underbody.
12. Remove front coolant pipe holder -1-.
12.1. Unscrew two hexagon-head bolts (M6 x 20) -2-.
Front coolant pipe holder
12.2. Detach and remove coolant pipe holder -1-.
13. Remove centre coolant pipe holder.
13.1. Unclip pipe holder -1- at the underbody support and push forwards a little.
Pipe holder
13.2. Version with TPM (Tire Pressure Monitoring):
Release and pull off cable plug -2-.
13.3. Detach pipe holder at the coolant pipes -arrows- and remove it.
13.4. Remove holder -3-. To do so, unscrew four external Torx screws (E14, M8) -4- and remove the holder -3-.
Coolant pipe holder on centre underbody
13.5. Secure coolant pipes using tie-wraps -arrows-.
Securing coolant pipes
14. Remove rear coolant pipe holder.
14.1. Unscrew two hexagon nuts (M6) -5-.
14.2. Detach rear pipe holder -6- at the coolant pipes and remove it.
Rear coolant pipe holder
15. Remove restraining straps -1- at the tank.
Restraining straps
15.1. Unscrew hexagon-head bolts (M8 x 40) -2- and remove the restraining straps.
15.2. Remove tank covering.
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.
16. Remove universal joint at the steering spindle.
Steering wheel must be in centre position.
16.1. Detach the universal joint.
The red lug -4- must not be pulled off at the same time because this will only increase the amount of assembly work required.
16.2. Remove screw -1- on the universal joint -2-. Pull universal joint -2- off the steering spindle -3-.
Removing and installing universal joint
17. Remove front-axle cross member.
-> 400919 Removing and installing front-axle cross member - section on "Removing" Service and Repair.
Removing fuel tank
Component overview:
Overview of fuel tank
1. Remove transverse restraining strap -1-.
1.1. Unscrew two hexagon-head bolts (M8 x 40) -2- on the left and right of the body.
Transverse restraining strap
WARNING
Highly inflammable 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.
Information
Get another person to help you remove and install the fuel tank.
2. Remove fuel tank.
Be careful of the tank flange.
2.1. Unclip the two clips -arrows- on the body and lift the fuel tank out of the vehicle with the help of another person. To do this, first tip the fuel tank to the right.
Clips on fuel tank
Installing fuel tank
Information
Get another person to help you remove and install the fuel tank.
1. Install fuel tank.
1.1. Guide the fuel tank into the body with the help of another person.
1.2. Clip clips -arrows- into the body mounting points.
Fuel tank clips
1.3. Insert transverse restraining strap -1- at the correct position on the fuel tank and secure using two hexagon-head bolts (M8 x 40) -2-.
=> Tightening torque: 23 Nm (17 ftlb.)
Transverse restraining strap for fuel tank
Subsequent work
1. Install front-axle carrier.
-> 400919 Removing and installing front-axle cross member - section on "Installing" Service and Repair.
2. Fit universal joint at the steering spindle. Use new fastening screw!
-> 489019 Removing and installing power-steering gear - section on "Installing" Service and Repair
2.1. Steering wheel must be in centre position.
Steering-wheel holder
2.2. Fit universal joint on the steering spindle.
Fit universal joint on the steering spindle while paying attention to the installation position -see arrows-.
Universal joint for steering gear
2.3. Fit and tighten new hexagon-head bolt (M8 x 35) -arrow- to universal joint.
=> Tightening torque: 23 Nm (17 ftlb.)
Universal joint
3. Install restraining straps -1- on the fuel tank.
3.1. Insert tank covering.
3.2. Attach restraining straps and secure using hexagon-head bolts (M8 x 40) -2-.
=> Tightening torque: 23 Nm (17 ftlb.)
Restraining straps
4. Install coolant pipe holder.
4.1. Install rear coolant pipe holder -4- and tighten hexagon nuts (M6).
=> Tightening torque: 10 Nm (7.5 ftlb.)
Rear coolant pipe holder
4.2. Install front coolant pipe holder -1-. Tighten two hexagon-head bolts (M6 x 20) -2-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
Front coolant pipe holder
4.3. Remove tie-wrap.
5. Install support -3- for centre underbody.
5.1. Secure support using four external Torx screws (E14, M10) -4-.
=> Tightening torque: 65 Nm (48 ftlb.)
Underbody support
6. Install pipe holder -1-.
6.1. Press in pipe holder at the coolant pipes -arrows-.
6.2. Latch pipe holder onto support.
6.3. Version with TPM (Tire Pressure Monitoring):
Connect cable plug -2-.
Pipe holder
7. Install filler neck.
-> 200719 Removing and installing filler neck - section on "Installing" Service and Repair.
8. Install fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Installing" Service and Repair.
9. Fuel the vehicle.
-> 2010EN Emptying and filling fuel tank.
10. Install carrier plate for battery.
=> Tightening torque: 23 Nm (17 ftlb.)
11. Install the battery.
-> 270619 Removing and installing battery - section on "Installing" 27061900 Removing and installing battery.
12. Start the engine.
13. Check all lines and connections for leaks.
14. Install rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair.
15. Install underbody panelling.
-> 519319 Removing and installing centre cover - Installing 519319 Removing and installing Cover For Centre Underbody.
-> 519419 Removing and installing rear cover - Installing 519419 Removing and Installing Cover for Rear Underbody.
-> 519219 Removing and installing front cover - section on "Installing" 519219 Removing and installing Cover For Front Underbody.
16. Install front wheels.
-> 44051900 Removing and installing wheel - section on "Installing" Removal and Replacement.
17. Remove steering-wheel holder.
18. Perform suspension alignment.
-> 44950300 Suspension alignment, complete Service and Repair.
19. Perform a test drive.