Removing Fuel Tank
Removing Fuel Tank
Tools
Tools:
Preliminary work
Preliminary work for removing fuel tank
1. Empty the fuel tank.
2. Remove the carbon canister. Details for loosening in installation location (wheel housing)
3. Remove rear axle (spring struts and rear axle housing) push it aside on the lifting platform (scope of work without further disassembly of rear axle)
Tools and materials
Required tools
Required Tools:
General warning notes
DANGER: Danger of poisoning from fuels.
- Gasoline is toxic.
- Inhaling vapours can cause irritation of the mucous membranes and eyes.
- It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
- Only work on the fuel system in well-ventilated rooms.
- Wear protective gloves that are fuel-resistant.
- Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
- Ensure that there is adequate ventilation and extract all fuel vapours.
- Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
- Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
- Pay attention to cleanliness when working on the fuel system.
DANGER: Danger of fire from fuel.
- Keep clear of ignition sources.
- Do not smoke.
- Disconnect battery.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO2 or dry powder fire extinguishers.
NOTE:
- The ignition must be switched off when working on the fuel system.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurized before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
Removing fuel tank
NOTE:
- The repair procedure may vary depending on engine type and country equipment. This relates in particular to components in the right wheel housing.
- The description relates to ORVR vehicles.
- Sealing rings must generally be replaced.
The following exploded drawing shows how the fuel tank is attached to the vehicle floor.
1. Open filler flap.
2. Screw the tank cap down. Then remove the rubber sleeve around the fuel filler neck, loosen the two fastening screws M6 x 25 and remove the ground cable.
3. Remove the fuel supply -1- at the connection unit and disconnect the 2 connection points -2 and 3-.
4. Pull fuel filler neck and degassing tank out of the wheel housing and secure with a piece of wire arrow -arrow- (picture shows degassing tank with carbon canister).
5. Then, loosen the stone guard on the right side. Unscrew screws -2-.
6. Remove line holder under the stone shield by pressing on the centre plug -arrow-. Replace holder.
7. Remove the centre underbody cover at the left and right of the longitudinal side members.
8. Remove rear heat shield. To do so, undo the three speed nuts and the two screws.
DANGER: Danger of injury due to heavy filled tank.
- For safety reasons, the tank should only be removed and installed when empty.
9. Loosen the tank attachment band, which runs in the direction of travel -arrows-. Then, position a transmission jack under the tank and secure the tank from falling using a belt. When doing so, make sure that the fuel lines are not damaged.
ATTENTION: Risk of damaging to fuel lines.
- Lines can become kinked or can crack.
- Never leave carbon canister hanging freely on the lines.
- A second person should hold the carbon canister during removal.
10. Undo and remove the remaining restraining straps with the help of a second worker. Slowly lower the tank with the transmission jack. Also carefully guide the degassing tank in the right wheel housing.