Remove/install fuel tank

AR47.10-S-4100S

Remove/install fuel tank

23.06.2017

Model

636 with engine 272, 646, 651

Model

639 with engine 112, 272, 642, 646, 651

Modification notes

19.06.2017

Method extended

Operation step 18

19.06.2017

Special tool 129 589 00 91 00 set of stop plugs inserted

Operation steps 4, 5, 7,

Shown with engine 646 and code H13 (Additional heat exchanger in passenger compartment)

1

Fuel tank

6

Vent line

10

Tensioning strap

2

Screw

7

Retaining bracket

12

Lines

3

Fuel feed line

8

Sealing

M3/3

Fuel pump with fuel level sensor

4

Fuel return line

9

Electrical connector

W33/4

Ground (tank filler neck)

Shown with code H12 (Auxiliary water heater)

5

Fuel line

M46/1

STH fuel metering pump

Shown with engine 112 and code HZ7 (Semi-automatically controlled air conditioning, TEMPMATIC in rear)

1

Fuel tank

2

Screw

3

Fuel feed line

7

Retaining bracket

8

Sealing

11

Hose

12

Lines

13

Nut

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 Danger

Risk of explosion caused by fuel vapors igniting, risk of poisoning caused by inhaling combustible gases and risk of injury caused by burns during and after operation of heater unit

Do not operate stationary heater, auxiliary heater or engine with heater booster in closed rooms or when refueling. Allow heater unit to cool down after operation and wear protective gloves.

AS83.70-Z-0002-01A

 

Remove/install

1

Drain fuel tank (1)

AR47.10-S-4001S

2

Remove fuel filler flap

AR88.60-S-6023S

3

Unscrew screw/bolt (2) at filler neck

4

Disconnect fuel feed line (3)

 Collect escaping fuel, plug fuel feed line (3).

 Record plug

*129589009100

5

Disconnect fuel return line (4)

Model 636, 639 with engine 642, 646, 651

 Collect escaping fuel, plug fuel return line (4).

 Record plug

*129589009100

6

Remove hose (11) from activated charcoal canister

Model 636 with engine 272
Model 639 with engine 112, 272

7

Remove fuel line (5) from STH fuel metering pump (M46/1)

Model 636 with engine 272, 646, 651
with code H12 (Auxiliary hot-water heater)
Model 636 with engine 272, 646, 651
with code HZ1 (Auxiliary heater (warm air))
Model 636 with engine 272, 646, 651
with code HZ9 (Heater booster)
Model 639 with engine 112, 272, 642, 646, 651
with code H12 (Auxiliary hot-water heater)
Model 639 with engine 112, 272, 642, 646, 651
with code HZ9 (Heater booster)

 Collect escaping fuel, plug fuel line (5).

 Record plug

*129589009100

8

Remove vent line (6) from vehicle frame

9

Loosen lines (12) on underbody

Model 636 with engine 272, 646, 651
with code H13 (Additional heat exchanger in passenger/load compartment)
with code HZ7 (TEMPMATIC semi-automatic air conditioning in rear)
Model 639 with engine 112, 272, 642, 646, 651
with code H13 (Additional heat exchanger in passenger/load compartment)
with code HZ7 (TEMPMATIC semi-automatic air conditioning in rear)

10

Remove mounting frame bow (7)



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Support fuel tank (1).

 Retaining bracket, fuel tank to longitudinal member

*BA47.10-N-1001-01A

11

Unscrew nut (13)

Model 636 with engine 272
Model 639 with engine 112, 272

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

12

Remove sealing (8)

 To do this lower fuel tank (1) until sealing (8) can be removed.

13

Secure fuel tank (1) with tensioning straps

 Commercially available devices/tools
Tensioning straps

14

Disconnect electrical connection (9) from ground (tank filler neck) (W334)

 To do this, lower fuel tank (1) until electrical connection (9) is accessible.

15

Unclip tensioning strap (10)

Model 636 with engine 272, 646
Model 639 with engine 112, 272, 642, 646

16

Disconnect electrical connection to fuel pump with fuel level sensor (M33)

 Installation: Note installation position of electrical line

If necessary



Install electrical line in existing bracket.

17

Remove fuel tank (1)

 Models 636, 639 with code T19 (Left sliding door)
Installation: Reposition soundproofing at filler neck.

18

Remove fuel feed module and lines at fuel tank (1)

When replacing the fuel tank (1).

AR47.20-S-7000S

19

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

20

Check fuel system on running engine for leaktightness

 Visual inspection only.

 Fuel tank

Number

Designation

Model 636, 639

BA47.10-N-1001-01A

Retaining bracket, fuel tank to longitudinal member

Nm

56