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PRE-RELEASE

Fuel tank, Z19

Fuel tank, Z19

Warning

Removal of the fuel tank involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work.

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


Important

Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.


To remove


1. Park the car on a lift.

2. Drain the fuel from the tank. See Draining fuel tank .

3. Raise the car.

4. Remove the rear exhaust system.


5. Detach both handbrake cables at the handbrake lever and retaining straps.


6. Remove the plastic screw of the filler pipe.


7. Disconnect the bleeder hose with tool 83 95 261 Tool, fuel line .

8. Detach the filler pipe from the connecting hoses of the tank.

9. Carefully move aside the filler pipe.

10. Detach the following fuel lines at the fuel filter holder with tool 83 95 261 Tool, fuel line .


10.a. Delivery and return lines

10.b. Cars with auxiliary heater : Quick coupling

11. Place a pillar jack under the tank.

12. Remove the front bolts of the strap holding the tank.


13. Lower the front edge of the tank.

14. Unplug the connector at the top of the tank.


15. Lower the tank.


To fit

Important

When fitting the filler pipe it is important to replace the rubber hose between the filler pipe and fuel tank. There is a risk of cracks appearing on the hoses in connection with continual tightening of hose clips, which can lead to fuel leakage.

It is also important to replace the old plastic screw with a new plastic one. In the event of a possible accident the plastic screw should give way in order to avoid damage to the filler pipe, which is also made of plastic.


Note

Spray the connector with Anti-corrosion agent, Contact Protect before connecting.



1. Carefully raise the tank, allowing the front edge to rest on the upright jack.

2. Plug in the connector above the tank.


3. Raise the tank all the way up, place the handbrake cables in the groove on the tank and screw on the strap holding the tank.

Make sure the wiring does not get pinched.


4. Fit the bleeder hose.


5. Fit the filler pipe to the connections on the tank using 30 16 235 Pliers .

6. Fit the filler pipe.

Tightening torque, new plastic screw 1.5 Nm (1.1 lbf ft)

7. Attach the fuel line to the auxiliary heater's fuel pump.


8. Attach the feed line and return line.

9. Fit the rear exhaust system.


10. Attach both handbrake cables at the handbrake lever and retaining straps.


11. Lower the car to the floor.

12. Fill any drained fuel

13. Start the engine and check the system for leaks.

14. Connect the diagnostic tool and clear any diagnostic trouble codes.


PRE-RELEASE