Removal and Replacement
WM 201019 Removing and installing fuel tank
Tools
Technical values
General warning notes
Group 20 - Fuel supply, control
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
Information
- 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 depressurised 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.
- Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.
Preliminary work
CAUTION
Heavy components
- Risk of squashing
-> Wear personal protective gear.
-> Get someone to help if necessary.
Information
When pulling off fuel supply lines, use cloths to soak up fuel (wrap around lines).
1. Relieve the fuel pressure =>
1.1. Switch off ignition.
1.2. Pull out the fuse for the fuel pump/control unit.
1.3. Start the engine and wait until the engine starts up automatically.
1. Remove (pull off) all three caps in the body shell openings.
1.1. Remove luggage compartment cover. -> 700619 Removing and installing luggage compartment trim (loadspace cover)
1.2. Pull off lid under the luggage compartment cover. To do this, cut through the side connections on the sound insulation. -1-
Cover and bodyshell openings
1.3. Loosen and fold up rear seats. -> 724819 Removing and installing rear seat - section on "Removing" 724819 Removing and installing rear seat
1.4. Pull off the two lids under the rear seats -2 and 3-. To do this, remove the carpeted floor.
Cover and bodyshell openings
2. Disconnect connection -2- at the venting flange.
Fuel-tank venting connections
Information
For safety reasons, the fuel tank should only be removed and installed when empty. For details of how to drain the fuel tank, see -> 2010EN Draining and filling the fuel tank Procedures
3. If the fuel level is high, drain the fuel tank now. -> 2010EN Draining and filling the fuel tank (draining and filling in fuel) Procedures
4. Disconnect fuel-tank flange connections under the rear seats.
4.1. Disconnect electric plug connection at the left fuel-tank flange. => Left flange
Left flange
4.2. Disconnect connections at the right fuel-tank flange. -1, 2 and 3- (3 only for auxiliary heater)
Right flange
5. Remove rear axle (spring struts and rear axle housing) and push it aside on a lifting platform (scope of work without disassembling the rear axle further). For details, see -> 420519 Removing and installing rear axle housing (chassis subframe) 420519 Removing and installing rear axle housing (chassis subframe)
Rear axle and lifting platform
6. Remove rear right wheel housing liner. -> 536919 Removing and installing rear wheel housing liner Service and Repair
Removing fuel tank
Overview =>
Fuel tank and accessories
1. Open flap. Open cap. => Fuel tank flap and cap
Fuel tank flap and cap
2. Release run-off line on the sealing sleeve at the filler tube and leave it hanging freely. The sealing sleeve -1- remains fitted.
Sealing sleeve
3. Detach filler neck from inside the wheel housing.
Filler neck
3.1. Remove screws -2 and 3-.
3.2. Disconnect vent line -1 in right illustration- behind the bore hole in the body at the plug connection and pull it out of the bore hole.
4. Remove heat protection panels at the fuel tank. => Heat protection panels at fuel tank
Heat protection panels at fuel tank
5. Loosen lines at the fuel tank and press them aside. => Lines at fuel tank
Lines at fuel tank
6. Before releasing the restraining straps, make sure that the fuel tank -1- cannot fall down. Position transmission jack -3- under the fuel tank. Support both sides with a suitable crossbar (wooden) -2-.
Supporting fuel tank with a cross bar and transmission jack
7. Remove securing devices (restraining straps). => Fuel tank mounting Remove the centre retaining bracket -4- last.
Fuel tank mounting
8. Slowly lower the fuel tank with the transmission jack and with the help of a second mechanic. Guide components down carefully when doing this. Pull the vent line out of the bore hole in the body -1 in left illustration-. Unclip lines at the top of the fuel tank on the body side while lowering the tank.
9. Remove the fuel tank from the transmission jack with the help of another mechanic if necessary.
Installing fuel tank
1. Lift the fuel tank on a transmission jack with the help of another mechanic if necessary.
2. Slowly move the fuel tank into installation position with the transmission jack and with the help of a second mechanic. Guide components into position carefully when doing this. Guide the vent line into the bore hole in the body -1 in left illustration-. Clip in lines at the top of the fuel tank on the body side while raising the tank.
Fuel tank mounting
2.1. Position and fit fastening devices (restraining straps) => Fuel tank mounting. Fit the centre retaining bracket first -4-. => Tightening torque: 23 Nm (17 ftlb.)
3. Remove the transmission jack after fitting the restraining straps. => Supporting fuel tank with a cross bar and transmission jack
Supporting fuel tank with a cross bar and transmission jack
4. Fit lines at the fuel tank. => Lines at fuel tank
Lines at fuel tank
5. Fit heat protection panels at the fuel tank. => Heat protection panels at fuel tank
Heat protection panels at fuel tank
6. Fit filler neck inside the wheel housing.
Filler neck
6.1. Fit screws -2 and 3-. Don't forget the ground strap (earth). => Tightening torque: 10 Nm (7.5 ftlb.)
6.2. Fit vent line -1 in right illustration- behind the bore hole in the body at the plug connection (pull on the line if necessary to check that it is secure).
7. Feed run-off line on the sealing sleeve through at the filler tube. => Sealing sleeve
Sealing sleeve
8. Seal the cap. => Fuel tank flap and cap
Fuel tank flap and cap
Subsequent work
1. Fit the rear axle (spring struts and rear axle housing). For details, see -> 420519 Removing and installing rear axle housing (chassis subframe) 420519 Removing and installing rear axle housing (chassis subframe)
Rear axle and lifting platform
2. Fit rear wheel housing liner at the right. -> 536919 Removing and installing rear wheel housing liner Service and Repair
3. Replace seals when refitting the flanges (if removed). => Seals on flanges
Seals on flanges
4. Fit the flanges using a wrench T10202. => Special tool on flange ring => Tightening torque: 110 Nm (81.5 ftlb.)
Special tool on flange ring
5. Fit fuel-tank flange connections under the rear seats.
5.1. Fit electric plug connection at the left fuel-tank flange. => Left flange
Left flange
5.2. Fit connections at the right fuel-tank flange. -1, 2 and 3- (3 only for auxiliary heater)
Right flange
6. Connect connection -2- at the venting flange.
Fuel-tank venting connections
7. Fit bodyshell cover. -- Be careful of the lugs on the bodyshell cover and the cut-out on the body panel when doing this.
Cover and bodyshell openings
8. Carry out remaining work if necessary.