Fuel Systems
Removing and installing fuel tankA. Removing and installing guide funnel (on all models with catalytic emissions control system)
Remove guide funnel (10)
Special Tool 123 589 05 33 00:
To do this, pull out the two rivets (arrows) with special tool 123 589 05 33 00.
Caution: Do not permit rivets to drop into fuel tank. They cancel the function of the splash bowl (fuel reserve quantity cannot be used).
Note: A guide funnel (10) is installed because of the smaller fuel dispensing nozzle for unleaded fuel. When replacing the fuel tank, a guide funnel must be installed.
Note: Models 107, 124, 126, 201 National version -USA. The guide funnel is provided with additional notches (arrows) to facilitate installation.
Production Breakpoints:
Warning: Pay attention to safety precautions. Risk of accident!
Disconnect battery ground cable
Release pressure in fuel tank by removing cap (40)
Check seal (41), replace if necessary.
Remove fuel gauge sender (B4). Only when exchanging fuel tank.
Remove fuel expansion tank (55).
Drain fuel tank (50). Carefully pump out fuel so that no fuel remains in the tank. Capacity approx. 85 liters.
Remove cup seal (60/1).
Remove fuel feed line (69) and fuel return line (70).
Note: Collect remaining fuel. Seal connections. Check suitability for reuse. Tightening torque 28 Nm (reference value).
Unscrew bolts (50/3, 4 ea.)
Installation note: Use washers (50/2). Tightening torque 20 Nm (reference value).
Remove fuel tank (50)
Installation note: Stick sealing pads (71, 71/1) and soundproofing strips (74) with MB universal adhesive 000 989 92 71 if necessary. Install reinforcing plates (5011) with reinforced side between bracket and fuel tank.
Remove fuel strainer (68). Clean and check suitability for reuse. Tightening torque 40 Nm.
Note: Remove fuel strainer with fuel tank in place.
Screw M 18 x 1.5 bolt with locking nut into fuel filter in place of the feed line, tighten locking nut and unscrew fuel strainer.
Replace seal (68/1).
Briefly run engine
Check connections for leaks.