Removal and installation of the fuel tank

The fuel tank with a capacity of 70 liters is made of steel sheet. The tank is located under the bottom of the body in the luggage compartment area.

Attention: Strictly follow the safety regulations when working on fuel supply systems, see p. 54.

Caution: A suitable fuel pump is required to draw fuel from the tank. To install the car on the goats, you need a garage jack and 4 reliable stands.

Withdrawal

Caution: Fuel may spill when removing the fuel tank. Gasoline and its vapors are poisonous and flammable, so the workplace must be well ventilated. Avoid getting fuel on the skin. Wear fuel resistant gloves. No open flame, fire hazard! Prepare a fire extinguisher.

Disconnect ground wire (-) battery.

Caution: Disconnecting the battery will erase the contents of the electronic memories, such as engine trouble codes or radio codes. Before switching off, also read the instructions in chapter "Removing and installing the battery".

Unscrew the filler cap of the fuel tank and pump fuel out of the tank with a pump.



If present, unscrew 2 screws -arrows- securing filler neck to body.


Vehicles from 9/94: Loosen the clamps and disconnect the 2 ventilation hoses from the bottom of the filler neck.

Loosen the right rear wheel nuts, jack up the vehicle and remove the rear wheel.



Unfasten and remove right rear wheel arch trim.



Vehicles up to 8/94: unscrew the fastener and remove the lower extension of the bumper.



Place a fuel-resistant container down. Vehicles up to 8/94: Loosen the fastening clamps and disconnect the injection and return fuel lines. To facilitate subsequent assembly, mark the fuel lines with adhesive tape. Vehicles from 9/94: Disconnect the fuel lines from the fuel level sensor. To release the quick-release fasteners, fully press both buttons and remove the fasteners, see illustration. The fittings and their corresponding quick-release fasteners have the same color code so that the fasteners cannot be mixed up during assembly.


Support the fuel tank with a jack.

Remove the retaining clamp bolts and carefully lower the fuel tank.

Disconnect the plug connector of the fuel level sensor and, if present, the fuel pump located in the tank.

Disconnect the ventilation hose.

Check if all wires and hoses are disconnected. Take out the fuel tank.

Installation

Before installation, check the fuel tank and retaining clamps for corrosion through and replace if necessary.

Place fuel tank in installation position and connect plug connectors for fuel gauge sender and fuel pump.



Attach the fuel tank, install the retaining clamps and tighten the mount.

In accordance with the markings, connect and secure the injection and return fuel lines with clamps.

Vehicles up to 8/94: Screw the fuel tank filler neck to the side wall of the body with two bolts. Attach and bolt the lower extension of the bumper.

Vehicles from 9/94 connect two hoses of the ventilation system to the filler neck of the fuel tank and secure them with clamps.

Fit and secure wheel arch trim.

Install the wheel and lower the car.

Tighten the wheel mount crosswise to 100 Nm.


Fill the fuel tank with fuel and screw on the filler cap.

Connect ground wire to battery (-).

If available, set the clock and enter the anti-theft code for the radio.

Check the operation of the fuel gauge on the instrument panel.