Remove/install fuel tank

AR47.10-P-4100MSA

Remove/install fuel tank

12.05.2020

Model

213, 238, 257, 290 with engine 256.9

Model

257 with engine 264

Modification notes

12.05.2020

Document completely revised.

1

Fuel tank

2

Separating points

3

Heat shield

6

Bolts

8

Tensioning straps

9

Screw

10

Fuel tank filler pipe

11

Shield

12

Screw

13

Washer

14

Ground cable

 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

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1.1

Empty fuel tank (1) with fuel pump.

Model 213, 238, 257, 290 with engine 256.9
If fuel pump is intact.

AR47.10-P-4001MSA

1.2

Empty fuel tank (1) using fuel transfer pump.

Model 213, 238, 257, 290 with engine 256.9
With defective fuel pump.

AR47.10-P-4000MSA

1.3

Empty the fuel tank (1).

In the case of a defective and intact fuel pump.

Model 257 with engine 264

AR47.10-P-4001OLC

2

Release and disconnect electrical connector of fuel pump.

Where fuel tank (1) is emptied using fuel transfer pump.

Model 213, 238, 257, 290 with engine 256.9

AR47.20-P-5710MSA

Model 257 with engine 264

AR47.20-P-5710OLC

3

Remove rear axle.

Model 238 with engine 256.9

AR35.10-P-0010LWO

Model 290 with engine 256.9

AR35.10-P-0010FRX

Model 213 (except 213.088/089/288/289) with engine 256.9

AR35.10-P-0010LWE

Model 257 with engine 256.9, 264

AR35.10-P-0010FR

4

Remove propeller shaft.

Model 290 with engine 256.9

AR41.10-P-0050MNI

Model 213, 238 with engine 256.9

AR41.10-P-0050LW

Model 257 with engine 256.9, 264

AR41.10-P-0050MSA

5

Remove the right rear fender liner.

Model 213, 238 with engine 256.9

AR88.10-P-1300LWE

Model 257, 290 with engine 256.9, 264

AR88.10-P-1302FR

6

Remove tank filler recess.

Model 213, 238 with engine 256.9

AR88.60-P-2001LWE

Model 257, 290 with engine 256.9, 264

AR88.60-P-2001FR

7

Remove screw (9).

 Screw/bolt, filler neck bracket to body

*BA47.10-P-1003-01P

8

Unscrew screw (12); remove washer(13) and heat shield(11).

 Installation: Insert pulley (13) between fuel tank filler pipe (10) and body.

 Screw/bolt, filler pipe to body

*BA47.10-P-1002-01P

9

Remove nut and remove ground line (14).

 M61

*BA00.10-P-1002-04A

10

Remove hose from activated charcoal canister.

Model 290 with engine 256.9

AR47.30-P-8212MNI

Model 213, 238, 257 with engine 256.9

AR47.30-P-8212MSA

Model 257 with engine 264

AR47.30-P-8212MRD

11

Seal openings using protective cover.

 Set of protective caps

*001589009100

12

Clean fuel lines in the area of the separating points (2).

Assembly cleaner

*BR00.45-Z-1028-04A

13

Release and disconnect fuel lines from separating points (2), seal openings with suitable stop plugs, and collect escaping fuel in a suitable container.

 Record plug

*129589009100

14

Support fuel tank (1).



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

15

Remove cap from heat shield (3).

16

Remove screws (6) and remove tensioning straps (8).

 Screw/bolt, fuel tank/tensioning strap to vehicle floor

*BA47.10-P-1001-01P

17

Lower fuel tank (1) slowly and remove.



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Aid of helper required.

18

Remove right fill level sensor.

When replacing the fuel tank (1).

Model 213, 238, 257, 290 with engine 256.9

AR47.50-P-0110MSA

Model 257 with engine 264

AR47.50-P-0110MND

19

Remove purge line from fuel tank(1).

When replacing the fuel tank (1).

20

Remove heat shield (3) from fuel tank(1).

When replacing the fuel tank (1).

21

Install in the reverse order.

22

Read out and delete fault memory.



Model 238 with engine 256.9

AD00.00-P-2000-06LWO



Model 213 with engine 256.9

AD00.00-P-2000-04B



Model 257 with engine 264
Model 257, 290 with engine 256.9

AD00.00-P-2000-06FR

 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

Perform an engine test run; when doing so, check the engine for proper operation and the fuel system for leaks.

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Fuel tank

Number

Designation

Model 213

Model 238

BA47.10-P-1001-01P

Screw/bolt, fuel tank/tensioning strap to vehicle floor

Nm

25

25

 Fuel tank

Number

Designation

Model 257

Model 290

BA47.10-P-1001-01P

Screw/bolt, fuel tank/tensioning strap to vehicle floor

Nm

25

25

 Fuel tank

Number

Designation

Model 213

Model 238

BA47.10-P-1002-01P

Screw/bolt, filler pipe to body

Nm

15

15

 Fuel tank

Number

Designation

Model 257

Model 290

BA47.10-P-1002-01P

Screw/bolt, filler pipe to body

Nm

15

15

 Fuel tank

Number

Designation

Model 213

Model 238

BA47.10-P-1003-01P

Screw/bolt, filler neck bracket to body

Nm

15

15

 Fuel tank

Number

Designation

Model 257

Model 290

BA47.10-P-1003-01P

Screw/bolt, filler neck bracket to body

Nm

15

15

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01