Remove/install fuel tank

AR47.10-P-4100LFD

Remove/install fuel tank

06.03.2020

Model

222 with engine 642, 656

Modification notes

25.07.2017

Repair method has been revised

Shown on model 222 with OM 642 engine

1

Fuel tank

2

Shackles

3

Connections

4

Filler neck

5

Nut

6

Nut

7

Threaded connection

 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1.1

Vent pressure in MAGIC BODY CONTROL, Active Body Control (ABC) using diagnostic system

Model 222 with engine 642, 656
with code 487 (Active Body Control (ABC))

Notes on Active Body Control suspension

Model 222 with engine 642, 656
with code 487 (Active Body Control (ABC))

AH32.50-P-0001-01N

AR32.50-P-0001-01LF



AD00.00-P-2000-04B

1.2

Vent pressure in AIRMATIC system using diagnostic system

Model 222 with engine 642, 656
except code 487 (Active Body Control (ABC))

Notes on AIRmatic

AH32.22-P-1000-02LF



AD00.00-P-2000-04B

2

Drain fuel tank (1)

AR47.10-P-4001LFD

3

Disconnect battery ground line

AR54.10-P-0003LF

4

Remove rear right fender liner

AR88.10-P-1400LF

5

Remove side underfloor paneling

AR61.30-P-1001LF

6

Remove the exhaust system

Model 222 with engine 642

AR49.10-P-7285LF

Model 222 with engine 656

AR49.10-P-7142OIA

7

Remove rear axle

AR35.10-P-0010LF

8

Remove the fuel filter housing

Model 222 with engine 656

AR47.20-P-5600OIA

9

Remove the heat shield below the fuel tank

10

Clean the fuel lines around the connections  (3)

Assembly cleaner

*BR00.45-Z-1028-04A

11

Unlock the connections  (3), pull off the fuel lines, and collect escaping fuel in a suitable container

12

Seal the openings

 Set of protective covers

*001589019100

 Record plug

*129589009100

13

Remove propeller shaft

AR41.10-P-0050LF

14

Unscrew nut (5)

15

Unscrew the nut  (6) and remove the ground line

16

Disconnect the screw connection  (7)

 Screw/bolt, filler neck bracket to body

*BA47.10-P-1002-01O

17

Remove the screws  at the shackles (2)

 Screw/bolt, filler neck to body

*BA47.10-P-1003-01O

18

Support fuel tank (1)



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

19

Unscrew the nuts at the fuel tank  (1) and remove the tensioning straps

 Nut/screw, fuel tank tensioning strap to vehicle floor

*BA47.10-P-1001-01O

20

Slowly lower the fuel tank  (1) and remove it together with the filler neck  (4)


Do not grab the fuel tank  (1) at the filler neck  (4).
Otherwise it will be damaged.

 Aid of helper required.

 Installation: Make sure the filler neck  (4) has been correctly positioned in the filler neck recess.

21

Correctly dispose of the fuel tank  (1)

When replacing the fuel tank (1).

22

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

23

Check fuel system for leaks with engine running

 Fuel tank

Number

Designation

Model 222

BA47.10-P-1001-01O

Nut/screw, fuel tank tensioning strap to vehicle floor

Nm

20

 Fuel tank

Number

Designation

Model 222

BA47.10-P-1002-01O

Screw/bolt, filler neck bracket to body

Nm

10

 Fuel tank

Number

Designation

Model 222

BA47.10-P-1003-01O

Screw/bolt, filler neck to body

Nm

12

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01