Remove/install fuel tank

AR47.10-P-4100GF

Remove/install fuel tank

09.03.2020

Model

168 with engine 166.940/960/990/995

Modification notes

23.06.2015

Underfloor protective wax inserted

Operation step 10

Shown on model 168 up to vehicle identification number: J546849

1

Fuel tank

2

Filler neck

3

Filling hose

4

Vent hose

5

Latch

6

Nut

7

Electrical connector

8

Activated charcoal canister

9

Fuel filter

10

Fuel lines

11

Hose clamps

12

Activated charcoal canister vent hose

13

Screw

14

Exhaust bracket

 

Remove/install

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove engine compartment paneling on the right, underfloor paneling in the center and underfloor paneling at the rear

AR61.20-P-1105GC

2

Empty fuel tank (1) as far as possible

AR47.10-P-4001GF

3

Remove filling hose (3) and bleed hose (4) on filler neck (2)

4

Close off filling hose (3) with a latch (5)

 Plug

*168589009100

5

Loosen clamps (11)

 Pliers for click clamps

*171589003700

6

Check clamps (11) for damage; replace if necessary.

7

Remove fuel lines (10) on fuel filter (9) and unfasten out of the line holder on underfloor (arrow)

8

Collect escaping fuel.

9

Close off fuel lines (10) and freely laid connections

 Record plug

*129589009100

10

Remove bleed hose for activated charcoal canister (12) on activated charcoal canister (8)

11

Disconnect electrical connector (7)

12

Remove exhaust bracket (14) in the vehicle floor

13

Remove fuel tank (1) from vehicle body, push exhaust system underfloor paneling downwards at the side and remove fuel tank (1)

 Installation: The self-locking nut (6) must be replaced.

 Nut with washer, fuel tank to body

*BA47.10-P-1001-01C

When replacing the fuel tank (1).



Wax is applied for preservation

Wax underbody protection (black, 1 liter container)

*BR00.45-Z-1017-05A

14

Remove latch (5) from filler line (3) and empty fuel tank (1) completely

 Use a suitable receptacle.

15

Remove fuel pump and fill level sensor

Only when installing new fuel tank (1).

AR47.20-P-7000GF

16

Dispose of fuel tank (1)

Only when installing new fuel tank (1).

17

Install in the reverse order



Check

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

18

Carry out engine test run and check fuel system for leaktightness

 Fuel tank

Number

Designation

Model 168.006/007/008/009/031/032/033/035/109/131/132/133/135

BA47.10-P-1001-01C

Nut with washer, fuel tank to body

Nm

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1017-05A

Wax underbody protection (black, 1 liter container)

A 004 989 79 20