Remove/install fuel tank

AR47.10-P-4100MCC

Remove/install fuel tank

17.10.11

28.3.08

Replacement of screw/bolts on fuel tank, added

Operation step 14

 

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

1

Drain fuel tank (1)

AR47.10-P-4001MCC

2

Unclip purge line (2) fixed to the fuel tank filler neck (1) and set aside

For engine 132.9

 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

3

Raise vehicle using the vehicle lift and remove underfloor paneling

Rechargeable drill / screwdriver

gotis://G_58.0_01.1

4

Remove diagonal struts

In model 451.4

AR61.10-P-5138MCC

5

Lower rear drive module

AR01.00-P-3050MCC

6

Remove fender liner in right rear fender

AR88.10-P-1400MCC

7.1

Remove purge line (2) on tank vent valve (Y58)

For engine 132.9

7.2

Unclip feed fuel line and return fuel line from the supports on the filler neck of the fuel tank (1)

For engine 660.9

 The feed fuel line is routed below and the return fuel line is routed above the filler neck of the fuel tank (1).

8

Separate the feed fuel line from the fuel filter and seal the fuel filter with a suitable stop plug

For engine 660.9

9

Unscrew screw/bolts (3) and remove reinforcement (4)



*BA63.50-P-1001-01B

10

Remove tank recess

 Unclip CBS rear end n the area of the tank recess.

AR88.60-P-2000MCC

11

Unscrew screw/bolts (5) from bracket (6)

12

Remove bolt (7), remove electrical line for ground (tank neck) and unhook on holder (6).

13

Support fuel tank (1) with a transmission jack and a removal fixture



*450589026200

Transmission jack
gotis://H_00.10_01.0

14

Remove screws/bolts (8)

 Installation: Replace self-locking bolts (8).



*BA47.10-P-1001-01F

15

Lower fuel tank (1) carefully until the electrical connector (9) is accessible at the fuel pump with fuel level sensor (M3/3)

16

Disconnect electrical plug (9) on fuel pump with fuel level sensor (M3/3)

17

Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)

18.1

Unlock fuel line (10) to fuel pump with fuel level sensor (M3/3), detach and close using a suitable stop plug

For engine 132.9

18.2

Unlock the return fuel line at the fuel pump with fuel level sensor (M3/3), detach and seal with a suitable stop plug

For engine 660.9

 The feed fuel line remains on the fuel tank (1), it is separated at the fuel filter.

19

Expose fuel line (10) on fuel tank filler neck (1)

For engine 132.9

20

Lower fuel tank (1) further and remove from removal fixture

 Aid of helper required.

If the fuel tank (1) is replaced the removed fuel tank (1) must be professionally disposed of.

See: 



Disposing of fuel tanks

OS47.10-P-0001-01A

21

Counterhold fuel tank (1), loosen lock ring (11) and remove

When replacing the fuel tank (1).

 Installation: Tighten the locking ring (11) until the arrow tips on the locking ring (11) and on the fuel tank (1) are opposite one another (arrow).



*450589000700

22

Carefully remove fuel pump with fuel level sensor (M3/3) from fuel tank (1) and place in a suitable container

When replacing the fuel tank (1).

 Installation: The installation position of the fuel pump with fuel level sensor (M3/3) is given by a cutout. Replace sealing ring on fuel pump with fuel level sensor (M3/3).

23

Remove activated charcoal filter (12) on fuel tank (1)

When replacing fuel tank (1) on vehicles with engine 132.9.

24

Expose purge line (2) on fuel tank (1) and take off

When replacing fuel tank (1) on vehicles with engine 132.9.

25

Unlock feed fuel line at the fuel pump with fuel level sensor (M3/3), detach and seal with a suitable stop plug

When replacing fuel tank (1) on vehicles with engine 660.9.

26

Press apart catch hooks on fuel filter bracket, remove fuel filter backwards out of the bracket and remove together with the feed fuel line

When replacing fuel tank (1) on vehicles with engine 660.9.

27

Install in the reverse order

 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

28

Perform test run engine and check fuel tank (1) and connections for leaks

Number

Designation

Model 451.3/4

BA47.10-P-1001-01F

Screw/bolt, fuel tank to body

Nm

13

Number

Designation

Model
451.3/4

BA63.50-P-1001-01B

Screw/bolt, reinforcement in right rear fender

Nm

15