Installation

Installing Protective Plates
- Check that heat deflector plate insulation and mounting lugs are intact.
- Reinstall protective plates on tank.
- Check that there are no loose objects in the tank.





Installing Abrasion Plate For Tank
- Install 6 self-adhesive pieces of foam rubber as illustrated. Foam rubber P/N 1 215 113-0.





Lifting Tank
- Slacken off nuts for rear retaining strap bracket (do not remove completely).
- Lift tank under body. Use mobile jack with fixture 999 5972.





Installing Tank
- Connect hose to expansion nipple and tighten hose clip.
- Lift rear of tank into correct position. Check right mounting as the tank is positioned.





Installing Front Mounting
- Install outer screws (2) loosely.
- The tank is hanging down at the front slightly.





Installing Propeller Shaft
- Check that the mating surfaces on the gearbox, final drive and propeller shaft flanges are free of dirt and rust.
- Insert the propeller shaft from the front.

NOTE: Locate the rear joint on the final drive flange.

Install:
- center bearing member
- center bearing screws NOTE: Washer between member and bearing.
- Do not tighten screws.





Installing Rear Joint Onto Drive Flange
- Install joint to flange as marked. Use new screws of the same length as the ones that have been removed:

^ 50 mm (1.97 in) red
^ 52.5 mm (2.07 in) white
^ 55 mm (2.17 in) blue
^ 60 mm (2.36 in) yellow
^ 65 mm (2.56 in) green

- Tighten screws to 8 Nm (5.9 ft.lb) and then crosswise to 30 Nm (22.1 ft.lb). Start with the same screw each time.





Installing Front Universal Joint
- Use new screws and nuts.
- Tighten screws crosswise to 50 Nm (36.9 ft.lb). Use tool 999 5244.





Tightening Center Bearing Screws
- Tighten screws for:

- center bearing member
- center bearing.
- Tightening torque 25 Nm (18.5 ft.lb).





Installing Retaining Straps
- Install retaining straps and tighten the front mounting.
- Tighten bracket/retaining straps.





Installing Fuel Tank Strut

Install:
- Right side mounting, separate heat deflector plate and muffler.
- Fuel tank strut.





Installing Fuel Tank Unit
- Install gasket in tank opening.
- Lubricate fuel tank unit mating surface with a thin layer of petroleum jelly.
- Carefully insert the fuel tank unit into the tank so that the pump mounting is not damaged by the tank splash guard.
- Seat fuel tank unit stamped markings in the plastic joints on the tank.
- Install a new collar and tighten with tool. 999 5448.

NOTE: When installing a new tank use a new collar. Failure to do so may result in fuel leakage.





Installing Wiring
- Route cabling, install rubber grommet and connect connector.
- Strip clamp as before.





Installing Cover

Install:
- Hoses.
- Cover over fuel tank unit.
- Refill with fuel.





Function Check
- Check leakage, pump and measuring functions.





Installing of Panels

Install:
- side panel.
- rear panel.
- rear wheel cover.
- cargo compartment carpet.
- cover above spare wheel.