Remove/install fuel tank

AR47.10-P-4100TX

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)

Engine 113, 156, 272, 273

AR47.10-P-4001TX

Engine 642

AR47.10-P-4001TQ

2

Remove both rear seat cushions

AR91.12-P-1020TX

3

Fold back the insulation mat (3)

4

Remove the left cap (2)

5

Release and disconnect electrical connector (4)

6

Remove rear stowage compartment

See Remove/install rear center console.

AR68.20-P-2020TX

7

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

8

Raise vehicle with vehicle lift

AR00.60-P-1000TX

9

Remove crossmember (5)



*BA62.30-P-1001-01C

10

Remove both rear sections of the underfloor paneling

AR61.30-P-1001TX

11

Remove exhaust system from flange connection back

Engine 272, 273

AR49.10-P-7280TX

Engine 113, 156

AR49.10-P-7280TY

Engine 642 see Remove/install rear muffler.

AR49.10-P-4951TQ

12

Remove heat shields (105d, 105e)

AR49.00-P-1000-01TX

13

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-0050-09TX

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

AR41.10-P-0050-04TX



*BA41.10-P-1002-01E

14

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-0050-05TX



*BA41.40-P-1001-01B



Long-life grease (NLGI grade 2)

Sheet 266.2

BB00.40-P-0266-02A

15

Remove heat shield (105f)

16

Unhook rear brake cables from automatic slack adjuster on parking brake

AR42.20-P-0525TX

17

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.

18

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.

19

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

20

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

21

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.

22

Lower fuel tank (1)

Remove fuel tank (1) if necessary.



Disposing of fuel tanks

OS47.10-P-0001-01A

23

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

24

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
219

BA62.30-P-1001-01C

Screw/bolt, crossmember to body

Nm

25

Number

Designation

Model
219

BA41.10-P-1002-01E

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

M12

Nm

60

Number

Designation

Model
219

BA41.40-P-1001-01B

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

Self-tapping screw

Nm

25