Remove/install fuel tank in transmission tunnel

AR47.60-P-1001RFW

Remove/install fuel tank in transmission tunnel

27.11.2019

Engine

780 in model 253.992/993

Modification notes

26.07.2019

Method description revised.

Operation step 1.

1

Electrical wiring harness

4

High-voltage lines

2

Reinforcement pipe, right

5

Fuel tank in transmission tunnel

3

Reinforcement pipe, left

5

Fuel tank in transmission tunnel

7

Lifting platform

8

Aggregate mount

9

Fuel tank protective frame

10

Tensioning straps

11

Screw

13

Hose

1

Electrical wiring harness

12

Check strap

14

Bolts

1.1

Electrical connectors

 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

 Danger

Risk of explosion caused by escaping hydrogen or overheating of the fuel tanks when working on the hydrogen system. Risk of frostbite to body parts caused by escaping gas and by touching component parts carrying gas when emptying fuel tanks. Risk of asphyxiation caused by inhalation of air diluted by hydrogen. Risk of burn injuries by coming into contact with an invisible pale blue hydrogen flame.

AS00.00-Z-0030-01B

 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.

AS00.00-Z-0035-01A

Topical note

Notes on fuel cell system

AH00.00-P-0022-01RFW

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Empty the fuel system with diagnostic device.

AR47.60-P-1006RFW

2

Ensure that the requirements for driving into the workshop are fulfilled.

Topical note

Requirements for driving into the workshop

AH00.00-P-0021-01RFW

3

Print out "tank system, fuel cell, form event log," fill out, and attach to the vehicle somewhere clearly visible.



OF00.00-P-3000-21RFW

4

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

AR47.70-P-1010RFW

 Diagnosis-based power disconnect is not possible in this case.

5

Switch off ignition and store transmitter key outside of transmitter range (min. 2 m).

6

Remove underfloor panels.

AR61.30-P-1001RFW

 Installation: Do not install the underfloor paneling until after the leak test.

7

Unclip electrical wiring harness (1) on right reinforcement pipe (2).

 Dismantling tool

*000589956300

8

Remove right reinforcement pipe (2) and left reinforcement pipe (3).

 Bolt, reinforcing tube to assembly frame for front fuel tank

*BA47.60-P-1002-01B

9

Remove the high-pressure line from the check valve on the high-pressure fuel circuit gas distributor.

AR47.25-P-0004RFW

10

Remove the electrical connectors and medium pressure line from the pressure regulating unit.

AR47.60-P-0028RFW

11

Remove the high-voltage lines (4) from the fuel tank protective frame in the transmission tunnel.

AR47.70-P-0010-02RFW

 Nut, high voltage line holder to fuel tank protective frame

*BA54.10-P-1022-02H

 Clip remover

*452589016300

12

Disconnect electrical connectors (1.1).

13

Remove, thread out and tie up the electrical wiring harness (1) on the fuel tank protective frame (9).

 The electrical wiring harness (1) is secured to the fuel tank protective frame (9) with several line brackets.

 Dismantling tool

*000589956300

If there is damage on the line bracket,



replace the line bracket.

14

Unscrew the screw (11) and place check strap (12) to one side.

 Bolt, assembly frame for rear fuel tank tensioning strap to body

*BA47.60-P-1004-01B

15

Remove the hose's expansion rivet (13).

 Dismantling tool

*000589956300

16

Position lifting platform (7) with aggregate mount (8) under the fuel tank in the transmission tunnel (5).



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

 Commercially available tool: universal aggregate mount

 Secure the fuel tank protective frame (9) with tensioning straps (10).
The fuel tank protective frame (9) and the fuel tank in the transmission tunnel (5) are firmly connected to each other.

17

Remove screws (14).

 Bolt, assembly frame for front fuel tank to body

*BA47.60-P-1001-01B

18

Carefully lower the fuel tank in the transmission tunnel (5) together with the fuel tank protective frame (9).



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

 Aid of helper required.
When lowering, pay attention to the clearance.

19

Remove the protective frame of the fuel tank in the transmission tunnel (5).

When replacing the fuel tank in the transmission tunnel (5).

AR47.60-P-1004RFW

20

Print out the "Information about the fuel tank" form, fill it out, and attach it permanently to the relevant fuel tank.

When replacing the fuel tank in the transmission tunnel (5).



OF47.60-P-3000-01RFW

21

Install in the reverse order.

22

Perform fuel system leak test.

AR47.60-P-0001RFW

 Tank system

Number

Designation

Engine 780 in model 253.992/993
with code ME02 (Fuel cell)

BA47.60-P-1001-01B

Bolt, assembly frame for front fuel tank to body

M10

Nm

58

 Tank system

Number

Designation

Engine 780 in model 253.992/993
with code ME02 (Fuel cell)

BA47.60-P-1002-01B

Bolt, reinforcing tube to assembly frame for front fuel tank

M12

Nm

106

 Tank system

Number

Designation

Engine 780 in model 253.992/993
with code ME02 (Fuel cell)

BA47.60-P-1004-01B

Bolt, assembly frame for rear fuel tank tensioning strap to body

M8

Nm

18

 High-voltage battery

Number

Designation

Model 253
with code ME02 (Fuel cell)

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

BA54.10-P-1022-02H

Nut, high voltage line holder to fuel tank protective frame

Nm

8

-