Remove/install fuel tank

AR47.10-P-4100GH

Remove/install fuel tank

6.12.06

7.11.00

Value changed from 170 Nm to 200 Nm

Figure in BA35.10-P-1001-01C for model 163 modified

*BA35.10-P-1001-01C

 

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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Drain fuel tank.

For an intact fuel pump, except model 163.113/128

AR47.10-P-4001GH

For a defective fuel pump and model 163.113/128

AR47.10-P-4000GH

2

Remove tank cap (2) and unhook from tank cover holder (4)

3

Remove left seat on the 3rd seat row

4

Remove cover (1) from left side paneling

5

Detach fuel lines for expansion reservoir and disconnect from filler neck

Vehicles from FIN A289565 except model 163.113/128

6

Open bayonet lock (3) and disconnect filler neck from guide funnel

 Installation: Replace O-ring and ensure correct seating. The bayonet lock (3) must be located above the pressure sensor.

7

Mount tank cap (2) and pull filler neck through into the interior

8

Remove fuel tank pressure sensor (B4/3)

Vehicles with code 494, USA version

AR47.50-P-0050GH

9

Remove fuel tank filler neck/ground screw connection (X36/4) from filler neck

Except model 163.113/128/

10

Cut into cable strap for retaining clip for fuel lines on filler neck and remove retaining clip

Vehicles from FIN A289565 except model 163.113/128

11

Raise vehicle with lifting platform

AR00.60-P-1000GH

12

Disconnect rubber seal (5) from underside of vehicle and pull filler neck out of vehicle interior

 Do not damage fuel lines on filler neck.

 Installation: Ensure correct seating of rubber seal (5) in the base of the body in order to avoid water entry.

13

Remove left rear wheel



Remove/install wheels, rotate if necessary

AP40.10-P-4050GH

14

Remove spare tire and spare tire carrier

Vehicles without code 849 Spare tire holder/spare tire

15

Cut into large securing cable band for filler neck on holder to longitudinal frame member

16

Remove holder from longitudinal frame member

17

Remove regeneration connection (77/2) and fresh air connection (77/4) on activated charcoal canister (77)

 Installation: Plug in lines according to the connection plan:

Engine 111

AR47.30-P-8212-01GJ

Engine 112, 113 except USA version

AR47.30-P-8212-01GI

Engine 112, 113 with code 494 USA version

AR47.30-P-8212-01GH

 Except model 163.113/128: The activated charcoal canister (77) and fuel tank (80) create a unit.

18

Detach vent hose

 At rear differential on rear of activated charcoal canister (77)

19

Remove shield for rear exhaust system

 Do not damage boot on rear axle shaft.

20

Remove rear propeller shaft on differential

See "Remove, install propeller shaft"

Model 163.113/136/154,

Model 163.128/157/172/175
with two piece propeller shaft

AR41.10-P-0050GH

Model 163.172 with single piece shaft

AR41.10-P-0050GI

21

Remove rear brake cable

 Unclip on underfloor of vehicle and remove right and left brake cable holder at frame.

22

Remove check strap for rear axle carrier from underfloor of vehicle

Vehicles as of VIN A145273, X708319

23

Remove rear left stone chipping guard

24

Support fuel tank (80) with a major assembly jack, remove lower tensioning straps (80/2) and release upper tensioning straps (80/2)

 Tensioning straps (80/2) are color-coded, cannot be mixed up.



*BA47.10-P-1001-01D

25

Remove longitudinal strut for tensioning straps (80/18)



*BA47.10-P-1002-01D

26

Remove linkage for headlamp regulation above

Vehicles with linkage for headlamp regulation above

27

Remove nuts for lower shock absorber mount on transverse control arm



*BA32.25-P-1001-03D

28

Remove rear axle carrier from frame floor assembly, support and lower as far as possible



*BA35.10-P-1001-01C

29

Lower fuel tank (80)

30

Remove longitudinal strut for tensioning strap (80/18) at the rear

31

Unclip lines on the side on fuel tank (80)

Vehicles as of VIN A289565, X754620

 Do not damage lines.

32

Release and disconnect electrical connector for fuel pump

33

Remove fuel return line (90/11) and fuel feed line (90/12)

 Do not kink fuel lines (90/11, 90/12).



*163589003700

34

Take out fuel tank (80)

 Do not damage filler necks and lines.

 Pass tapered side of filler neck (arrow) between frame and body. The filler neck and fuel tank (80) cannot be separated.

35

Install in the reverse order

36

Dispose of fuel tank (80)

When replacing the fuel tank (80)



Disposing of fuel tanks

OS47.10-P-0001-01A

Number

Designation

Model 163

BA35.10-P-1001-01C

Self-locking bolt, rear axle carrier at front and rear of frame floor

Nm

200

Number

Designation

Model
163.113/
128/136/
154/157/
172/175

BA47.10-P-1001-01D

Bolts for tensioning straps

Nm

20

BA47.10-P-1002-01D

Longitudinal strut for check straps

Nm

20

Number

Designation

Model 163

BA32.25-P-1001-03D

Self-locking nut, shock absorber to lower wishbone

Nm

85