Remove/install fuel tank

AR47.10-P-4100RF

Remove/install fuel tank

02.07.2020

Model

253 with engine 177, 264, 274.9, 276.8, 642, 651.9, 654.9, 656

Shown on fuel tank without code 494 (USA version) and without code 916 (Fuel tank with 66 l))

1

Fuel tank

5

Stiffener

1a

Screws

6

Fuel line

1c

Tensioning strap

7

Fuel line

2

Heat shield

Shown: fuel tank with code U77 (BlueTEC (SCR) diesel exhaust gas cleaning) and without code 916 (fuel tank with 66 l))

1

Fuel tank

8

Screw

9

Screw

12

Ground line

20

Heat shield

Shown on fuel tank without code 494 (USA version) and without code 916 (Fuel tank with 66 l))

1

Fuel tank

1a

Screw

1c

Tensioning strap

5

Stiffener

6

Fuel line

7

Fuel line

Shown on model 253.954 with engine 274.9

17

Power electronics

18

Screw

19

Screws

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Model 253.311/911 with engine 654.9
Model 253.353/354/953/954 with engine 274.9

AS00.00-Z-0035-01A

 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

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-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

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

Model 253.311/911 with engine 654.9
Model 253.353/354/953/954 with engine 274.9

AH00.00-Z-0300-01A

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

Perform power disconnect of high-voltage on-board electrical system.

Model 253.311/911 with engine 654.9
Model 253.353/354/953/954 with engine 274.9

AR54.10-P-1150LVH

2

Disconnect ground line of on-board electrical system battery (G1).

AR54.10-P-0003LW

3

Secure vehicle on vehicle lift.

AR00.60-P-0100CW

4

Empty fuel tank (1).

AR47.10-P-4001RF

5

Release and disconnect electrical connectors on feed unit.

AR47.20-P-5710RF

6

Remove rear bottom engine compartment lining.

AR61.20-P-1105LW

 Installation: Only install rear lower engine compartment lining after leak test.

7

Remove left and right underfloor paneling.

AR61.30-P-1001LW

 Installation: Only install left and right underfloor paneling after a leak test.

8

Remove stiffener (5).

 Bolt, rear reinforcement to frame floor assembly

*BA61.10-P-1004-01L

9.1

Remove center exhaust system.

Model 253 with engine 177, 264, 274.9, 276.8

Model 253 with engine 177

AR49.10-P-7283MNG

Model 253 with engine 276.8

AR49.10-P-7283MMV

Model 253 with engine 274.9

AR49.10-P-7283RF

Model 253 with engine 264

AR49.10-P-7283MRI

9.2

Remove SCR catalytic converter.

Model 253 with engine 642, 651.9

Model 253 with engine 642
with code U77 (Diesel Emission control BLUETEC (SCR))

AR14.40-P-2006OGW

Model 253 with engine 651.9
with code U77 (Diesel Emission control BLUETEC (SCR))

AR14.40-P-2006LWB

10

Remove rear muffler.

Model 253 with engine 177

AR49.10-P-4952MNG

Model 253 with engine 264, 274.9, 276.8, 642, 651.9, 654.9, 656

AR49.10-P-4952RF

11

Remove propeller shaft.

AR41.10-P-0050LWX

12

Remove rear axle.

AR35.10-P-0010LWX

13

Remove tank filler recess.

AR88.60-P-2000LW

14

Unscrew screw (8) and remove heat shield (20).

 Screw/bolt, filler pipe to body

*BA47.10-P-1002-01P

15

Remove screw (9).

 Screw/bolt, filler neck bracket to body

*BA47.10-P-1003-01P

16

Remove nut and take off ground line (12).

 Fuel tank filler neck ground point

*BA00.19-P-1027-01E

17

Clean fuel lines (6, 7) near the separating points on the right side of the frame floor assembly.

Assembly cleaner

*BR00.45-Z-1028-04A

18

Release and disconnect fuel lines (6, 7) and catch escaping fuel in a suitable container.

19

Seal openings on fuel lines (6, 7) with suitable stop plugs.

 Record plug

*129589009100

20

Support power electronics (17) with high-voltage distributor and secure to prevent from falling down.

Model 253.354/954 with engine 274.9



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

21

Remove screws (18, 19).

Model 253.354/954 with engine 274.9

 Bolt, bracket for power electronics to body

*BA08.20-P-1001-01I

 High-voltage distributor to body

*BA54.10-P-1004-03E

22

Lower power electronics (17) with high-voltage distributor.

Model 253.354/954 with engine 274.9



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B


Do not put electric lines under tension.
Otherwise the high-voltage on-board electrical system may be damaged.

23

Remove hoses from activated charcoal canister and seal openings with suitable stop plugs.

Model 253 with engine 177, 264, 274.9, 276.8

AR47.30-P-8212LWA

 Record plug

*129589009100

24

Support fuel tank (1) and secure to prevent it from falling down.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

25

Unclip cap from heat shield (2).

26

Unscrew screws (1a) and remove tensioning straps (1c).

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

*BA47.10-P-1001-01P

27

Carefully lower fuel tank (1).

 Aid of helper required.

28

Remove right fill level sensor.

When replacing the fuel tank (1).

AR47.50-P-0110RF

29

Remove heat shield (2).

When replacing the fuel tank (1).

30

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

31

Perform engine test run and check leak tightness of fuel system.

32

Install left and right underfloor paneling.

AR61.30-P-1001LW

33

Install rear lower engine compartment lining.

AR61.20-P-1105LW

 Ground points

Number

Designation

Model 253 (except 253.99)
up to model year 2020

BA00.19-P-1027-01E

Fuel tank filler neck ground point

W33/4

Nm

10

 Control units

Number

Designation

Model 253
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA08.20-P-1001-01I

Bolt, bracket for power electronics to body

Nm

23

 Fuel tank

Number

Designation

Model 253

BA47.10-P-1001-01P

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

Nm

25

 Fuel tank

Number

Designation

Model 253

BA47.10-P-1002-01P

Screw/bolt, filler pipe to body

Nm

15

 Fuel tank

Number

Designation

Model 253

BA47.10-P-1003-01P

Screw/bolt, filler neck bracket to body

Nm

15

 High-voltage distributor

Number

Designation

Model 253
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

Model 253
with code ME02 (Fuel cell)

BA54.10-P-1004-03E

High-voltage distributor to body

Nm

6

-

 Frame floor assembly

Number

Designation

Model 253

BA61.10-P-1004-01L

Bolt, rear reinforcement to frame floor assembly

Nm

24

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01