Remove/install tank recess

AR88.60-P-2000LW

Remove/install tank recess

30.06.2019

Model

205

Model

253

Modification notes

01.03.2016

Method to unlock tank filler recess changed.

Operation step 8.2

Shown on model 205.0 with code U77 (Diesel exhaust treatment BLUETEC (SCR))

1

Tank filling recess

2

Rubber plug

3

Hinge

4

Fuel filler flap

5

Catch hook

6

Cap (with code U77 (Diesel exhaust treatment BLUETEC (SCR)))

7

Electrical connector

M14/10

Tank cap central locking actuator

Shown on model 205.0 with code U77 (Diesel exhaust treatment BLUETEC (SCR))

1

Tank filling recess

1.1

Catch hook

1.2

Fitting (model 205)

8

Extraction hook

9

Seal

 Warning

Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue

Pour AdBlue into suitable containers only. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS14.40-Z-0001-01A

 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

Notes on use, material properties and handling of AdBlue®

AH14.40-N-0001-01A



Remove

1

Detach fender liner in area of tank filler recess (1)

Model 205

AR88.10-P-1400LW

2

Remove drain hose from fitting (1.2)

Model 205

3

Unlock fuel filler flap (4) from catch hook (arrow A) and remove from hinge (3)

4

Unclip check strap from bracket (arrow B)

5

Unscrew cap (6)

Model 205, 253
with code U77 (Diesel Emission control BLUETEC (SCR))

6

M14Unclip tank cap central locking actuator (10) from catch hook (5) and pull out until electrical connector (7) is accessible

7

Disconnect electrical connector (7) and remove tank cap central locking actuator (M14/10)

8.1

Install rubber plugs (2)

If rubber plugs (2) are installed.

8.2

Drill tank filler recess (1) on release holes (arrows C, D, E, F) with drill Ø 3 mm

If rubber plugs (2) are not installed.


Do not drill too low.
Otherwise the catch hooks(1.1) behind can be damaged.

9

Unlock catch hook (1.1) behind release holes (arrows C, D, E, F) with extraction hook (8) and simultaneously pull tank filler recess (1) out of fender

 Extraction hook

*140589023300

10

Coat seal on tank filler recess (1) on filler neck with lubricant

Lubricant

*BR00.45-Z-1032-06A

11

Remove tank filler recess (1) from fender

 Install seal on tank filler recess (1) on filler neck.

 Model 205
Pull fitting (1.2) out of seal (9).



Install

12

Install rubber plug (2) in tank filler recess (1)

Only if tank filler recess (1) has not been replaced.

13

Coat seal (9) in area of opening for fitting (1.2) with lubricant

Model 205

Lubricant

*BR00.45-Z-1032-06A

14

Coat seal on tank filler recess (1) in area of filler neck with lubricant

Lubricant

*BR00.45-Z-1032-06A

15

Insert tank filler recess (1) at front into fender

16

Push fitting (1.2) through seal (9)

Model 205

17

Install seal on tank filler recess (1) on filler neck

18

Guide electrical connector (7) through opening in tank filler recess (1)

19

Clip tank filler recess (1) with catch hooks (1.1) into fender

20

Contact electrical connector (7) to tank cap central locking actuator (M14/10) and clip in tank cap central locking actuator (M14/10)

21

Screw on cap (6)

Model 205, 253
with code U77 (Diesel Emission control BLUETEC (SCR))

22

Clip check strap into bracket (arrow B)

23

Slide tank cap (4) onto hinge (3) and arrest

24

Install drain hose on fitting (1.2)

Model 205

25

Install fender liner

Model 205

AR88.10-P-1400LW

Repair materials

Number

Designation

Order number

BR00.45-Z-1032-06A

Lubricant

A 000 989 08 60