Removal and Replacement
WM 201019 Removing and installing fuel tank - Turbo
Tools
Technical values
Preliminary work
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.
-> 4X00IN01 Lifting the vehicle 4X00IN01 Lifting the vehicle
2. Place protective covers on the vehicle to avoid damaging the vehicle.
3. Disconnect the battery.
-> 2706IN Work instructions after disconnecting the battery 2706IN00 Work instructions after disconnecting the battery
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.
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.
5. Display a warning sign in a clearly visible position in the work area or attach it to the vehicle.
Example of warning sign
6. Remove front wheels.
Use special tool Socket-wrench insert 300.
-> 44051900 Removing and installing wheel - section on "Removing" 440519 Removing and installing wheel
Wheel with central bolt. Use special tools socket-wrench insert 9796 and assembly aid 9794.
-> 440519 Removing and installing wheel with central bolt - section on "Removing" 440519 Removing and installing wheel
7. Remove rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
8. Remove fuel level sensor.
-> 201519 Removing and installing fuel level sensor - Turbo - section on "Removing" Service and Repair
9. Drain the fuel tank.
Fuel transfer unit WE WE1262 should be used.
-> 200317 Draining and filling fuel - Turbo
10. Remove the filler neck.
-> 200719 Removing and installing filler neck - Turbo - section on "Removing" Service and Repair
11. Remove underbody panelling.
-> 519419 Removing and installing rear cover - section on "Removing" 519419 Removing and Installing Cover for Rear Underbody
-> 519320 Removing and installing centre cover - section on "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 final drive.
-> 398819 Removing and installing front final drive - section on "Removing" 398819 Removing and installing four-wheel final drive
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.
13. Remove universal joint at the steering spindle.
13.1. Precondition: Steering wheel must be in centre position.
13.2. Remove universal joint.
Removing and installing universal joint
Make sure not to pull the red lug -4- down as well because this will only increase the amount of assembly work required.
Loosen screw -1- on the universal joint -2- and remove it. Pull the universal joint off the steering spindle -3-.
14. Remove front-axle cross member.
-> 400919 Removing and installing front-axle cross member - section on "Removing".
Information
Component information
Overview
Component overview of fuel tank
Removing fuel tank
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.
1. Unclip the two clips on the body -arrows-.
Clips securing fuel tank
Information
Get another person to help you remove and install the fuel tank.
2. Remove the fuel tank.
Fuel tank
2.1. To do this, first tilt the tank towards the rear and carefully guide the tank flange over the edge of the body -arrow-.
Installing fuel tank
Information
Foam parts must be fitted on the fuel tank. Affix new parts to the specified positions if necessary.
1. Affix foam part -1- to the tank flange of the fuel tank if necessary.
Position of foam part on tank flange
Side view
Side view of foam part on tank flange
2. Affix foam part -2- for the bulkhead if necessary.
Foam part for bulkhead
Information
Get another person to help you remove and install the fuel tank.
3. Install the fuel tank.
Clips securing fuel tank
3.1. Clip the clips into the body mounting points -arrows-.
3.2. Insert transverse restraining strap at the correct position on the tank and secure with two M8 screws.
=> Tightening torque: 23 Nm (17 ftlb.)
Subsequent work
1. Install front-axle carrier.
-> 400919 Removing and installing front-axle carrier - section on "Installing"
-> 4001TW Tightening torques for front axle 4001TW Tightening torques for front axle
2. Fit universal joint at the steering spindle. Use new fastening screw!
2.1. Precondition: Steering wheel must be in centre position.
Steering-wheel holder
2.2. Fit universal joint on the steering spindle.
Universal joint for steering gear
Fit the universal joint on the steering spindle while paying attention to the installation position -see arrows-.
2.3. Fit and tighten M8 screw -arrow- on the universal joint.
Universal joint
=> Tightening torque: 23 Nm (17 ftlb.)
3. Install front final drive.
-> 398819 Removing and installing front final drive - section on "Installing" 398819 Removing and installing four-wheel final drive
4. Install the filler neck.
-> 200719 Removing and installing filler neck - Turbo - section on "Installing" Service and Repair
5. Install fuel level sensor.
-> 201519 Removing and installing fuel level sensor - Turbo - section on "Installing" Service and Repair
6. Fuel the vehicle.
-> 200317 Draining and filling fuel - Turbo
7. Connect the battery.
-> 2706IN Work instructions after disconnecting the battery 2706IN00 Work instructions after disconnecting the battery
8. Check all lines and connections for leaks.
9. Install rear part of front right wheel housing liner.
-> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
10. Install underbody panelling.
-> 519319 Removing and installing centre cover - section on "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
11. Install front wheels.
Use special tool Socket-wrench insert 300.
-> 44051900 Removing and installing wheel - section on "Installing" 440519 Removing and installing wheel
Wheel with central bolt. Use special tools socket-wrench insert 9796 and assembly aid 9794.
-> 440519 Removing and installing wheel with central bolt - section on "Installing" 440519 Removing and installing wheel
12. Remove steering-wheel holder.
13. Remove protective covers from the vehicle.
14. Perform suspension alignment.
-> 44950300 Suspension alignment, complete Service and Repair
15. Perform a test drive.