Remove/install fuel tank

AR47.10-P-4100T

Remove/install fuel tank

17.10.11

28.1.08

Repair method has been revised

 

Remove/install

 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

 Danger!

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

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

AS00.00-Z-0010-01A

 Danger!

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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Drain fuel tank (1)

Engines 628, 642, 646, 647, 648

AR47.10-P-4001T

Engine 629

AR47.10-P-4001TJ

Engine 112, 113, 156, 271, 272, 273

AR47.10-P-4001TB

2.1

Remove rear seat cushion

Model 211.0 without code 287 Through-loading feature

AR91.12-P-1020T

2.2

Position rear seat cushion upright

Model 211.0 with code 287 Through-loading feature,
model 211.2

See Remove/install rear seat cushions:

Model 211.0 with code 287 Through-loading feature

AR91.12-P-1020TA

Model 211.2

AR91.12-P-1020TB

2.3

Enable access to left cap (2)

Model 211.6 according to body

 Pay attention to notes from body manufacturer.

3

Fold back the insulation mat (3)

4

Remove the left cap (2)

5

Release and disconnect electrical connector (4)

6

Unscrew nut (1a) from grub screw of the fuel tank (1)

7

Raise vehicle with vehicle lift

AR00.60-P-1000T

8

Remove crossmember (5)



*BA62.30-P-1001-01A

9

Remove both rear sections of the underfloor paneling

AR61.30-P-1001T

10.1

Remove exhaust system from flange connection back

Engine 112, 113 except 113.990

AR49.10-P-7280TB

Engine 271

AR49.10-P-7280TK

Engines 646, 647

AR49.10-P-7280T

Engine 628

AR49.10-P-7280TC

Engine 272, 273

AR49.10-P-7280TS

10.2

Remove exhaust system from pipe connection

Engine 648

AR49.10-P-7281T

10.3

Remove rear muffler

Engine 642

AR49.10-P-4951TI

Engine 629

AR49.10-P-4951TJ

10.4

Remove complete exhaust system

Engines 113.990, 156

AR49.10-P-7000TB

11

Remove heat shields (105d, 105e)

12

Detach propeller shaft (106) from rear axle center assembly

 The flexible coupling remains on the propeller shaft (106). If the fitted sleeves are jammed: 

Loosen fitted sleeves for flexible coupling at flange of rear axle center assembly.

AR41.10-P-0050-09DA

Installation: Mount propeller shaft (106) on rear axle center assembly.

AR41.10-P-0050-04I



*BA41.10-P-1002-01A

13

Unscrew screw/bolts from propeller shaft center support bearing (106a) and remove rear part of the propeller shaft (106)

 Installation: Assemble propeller shaft (106) in correct order. Only tighten propeller shaft intermediate bearing (106a) screw/bolts after fixing flexible coupling to rear axle center assembly.

AR41.10-P-0050-05DA



*BA41.40-P-1001-01A



Long-life grease (NLGI grade 2)

Sheet 266.2

BB00.40-P-0266-02A

14

Remove heat shield (105f)

15

Unhook rear brake cables from automatic slack adjuster on parking brake

AR42.20-P-0525T

16

Disconnect filler hose (6) at fuel tank (1)

 Collect fuel which flows out.

 Installation: Check filler hose (6) and hose clamp for damage and replace if necessary.

17

Detach connector hose (7s) from fuel feed line (7v) and fuel return line (7r)

 Do not use any pointed or sharp-edged tools for removing the connector hoses (7s); otherwise, they can get damaged.

 Fuel return line (7r) is only available on vehicles with diesel engine.

 Collect fuel which flows out.

 Installation: Replace the CLIC clamps (A). Never use screw and nut clamps or spring bracket clamps, as air-tightness will be lost.

 Installation: Check connector hoses (7s) for damage and replace if necessary.

18

Support fuel tank (1) with a transmission jack and a transmission plate

Transmission jack 2.0-7.0
t gotis://H_00.10_01.0

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

19

Detach retaining straps (8) on underfloor and lower the fuel tank (1) slightly



*BA47.10-P-1004-01E

20

Detach connector hoses (9s) from vent lines (9)

 Do not use any pointed or sharp-edged tools for removing the connector hoses (9s); otherwise, they can get damaged.

 Installation: Replace the CLIC clamps (A). Never use screw and nut clamps or spring bracket clamps, as air-tightness will be lost.

 Installation: Check connector hoses (9s) for damage and replace if necessary.

21

Lower fuel tank (1)

Remove fuel tank (1) if necessary.



Disposing of fuel tanks

OS47.10-P-0001-01A

22

Install in the reverse order



Checking

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

23

Perform engine test run and check exhaust and fuel system for leaks

 Determine the cause of leaks if any and eliminate them; otherwise, there is a possibility of malfunction as well as personal injury, and property and environmental damage.

Number

Designation

Model
211

BA62.30-P-1001-01A

Screw/bolt, crossmember to body

Nm

25

Number

Designation

Model
211

BA41.10-P-1002-01A

Self-locking nut, flexible coupling to rear propeller shaft or rear axle differential.

M10

Nm

40

M12

Nm

60

Number

Designation

Model 211

BA41.40-P-1001-01A

Screw/bolt, propeller shaft center support bearing to frame floor assembly

Self-tapping screw

Nm

25

Bolt with washer

Nm

-

Bolt with collar and self-centering tip

Nm

-

Bolt with collar and without self-centering tip

Nm

-

Number

Designation

MODEL
211

BA47.10-P-1004-01E

Fuel tank retaining straps to underfloor

M 8

Nm

20

M 18

Nm

-