ar4710p4100pi

Remove/install fuel tank

Type ar · topic 47.10 · version 0201 · 2006-08-15

Applies to: MODEL 203, 209 with engine 642

Where it sits

Function group 1 Engine › 47 Fuel system, powertrain energy supply › 47.10 Fuel tank — Series 203 · Series 209

EinPAS 16 Fuel/power supply to engine › 16.10 Fuel supply › 16.10.40 Fuel tank/filling fixture — Series 203 · Series 209

Also applies to engines/gearboxes: 642 ***

AR47.10-P-4100PI

Remove/install fuel tank

26.7.06

MODEL 203, 209 with engine 642

Remove/install fuel tank

P47.10-2066-09

1 Cap

2 Electrical connector

4 Hand brake cable

5 Relay lever

6 Outer cable

7 Fender liner

8 Hose clamps

9 Fuel hoses

10 Bolt

11 Filler pipe

12 Floor coverings

B4/1 Left fuel level sensor

Remove/install fuel tank

P47.10-2078-06

13 Fuel hose

14 Fuel feed pipe

15 Hose clamp

16 Shield

17 Fuel tank

18 Fuel tank retaining straps to underbody

19 Propeller shaft

Modification notes

16.5.06

"Disconnect/connect battery ground line" removed

Remove/install

Danger!

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

Align vehicle between columns of lifting platform and position four support plates at lifting platform support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Empty fuel tank (17)

AR47.10-P-4001PI

Fuel tank capacity

*BF47.10-P-1001-01A

2

Remove rear axle.

AR35.10-P-0010P

3

Remove end cover (1) of body

4

Disconnect plug in electrical plug connection (2) on fuel level sensor, left half of tank (B4/1)

5

Detach hand brake cable (4) at relay lever (5)

6

Pull outer cable (6) out of fixture

Press together two retaining tabs (arrows) for this step.

7

Remove fender liner (7) on the right rear

AR88.10-P-1400P

8

Take off hose clamps (8)

Installation: Check hose clamps (8) for damage, replace if necessary.

9

Detach fuel hoses (9)

In the event of fixed fuel lines (9) cut these with a knife and then detach. There is otherwise risk of fixed fuel lines (9) shearing off the connections at the fuel tank (17).

10

Remove bolt (10) on filler pipe (11)

11

Remove floor coverings (12)

12

Detach fuel line (13) on fuel pipe (14)

Clamp off feed hose (13).

Installation: Check hose clamp (15) and fuel hose (13) for damage, replace if necessary.

Clamp

*000589403700

13

Remove shield (16)

14

Support fuel tank (17)

15

Unscrew retaining straps for fuel tank to underbody (18) at body

Fuel tank retaining straps to underbody

*BA47.10-P-1004-01E

16

Remove fuel tank (17)

After removing the fuel tank (17), tie up propeller shaft (19) with a cable tie.

17

Dispose of fuel tank (17)

Only when replacing fuel tank (17)

Disposing of fuel tanks

OS47.10-P-0001-01A

18

Install in the reverse order

Fuel tank

Number

Designation

Model
203, 209 without code 494/835

Model
203, 209 with code 494/835

BA47.10-P-1004-01E

Fuel tank retaining straps to underbody

M 8

Nm

20

20

M 18

Nm

60

60

Fuel tank

Number

Designation

Model
203

Model
209

BF47.10-P-1001-01A

Fuel tank capacity

Total filling capacity

Liters

62

62

Reserve capacity

Liters

8

8

Remove/install fuel tank

Clamping device

000 589 40 37 00

Referenced documents