Removal and Replacement
WM 201019 Removing and installing fuel tank
Tools
Technical values
Preparatory work for fuel tank
1. Observe warning notes. -> 2X00IN General warning notes for working on the high-voltage electrical system Procedures
2. Isolate the high-voltage electrical system from the power supply and complete the relevant documentation. -> 2X00IN Isolating high-voltage electrical system from power supply/Starting high-voltage electrical system Procedures
3. Disconnect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery
4. Remove the rear axle carrier. -> 420119 Removing and installing rear axle housing - section on "Removing" 420119 Removing and installing rear axle housing
5. Remove rear wheel housing liner at the right. -> 536919 Removing and installing rear wheel housing liner Service and Repair
6. Remove underbody cover at the left and right. -> 519319 Removing and installing cover for centre underbody Service and Repair
7. Remove rear seat. -> 724819 Removing and installing rear seat - section on "Removing" 724819 Removing and installing 1/3-split folding rear seat 724819 Removing and installing 2/3-split folding rear seat
Removing fuel tank
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.
Information
For safety reasons, the fuel tank should only be removed and installed when empty. -> 200317 Draining and filling fuel Procedures
Component overview of degassing tank and fuel tank in the unit
1. Open the filler flap and unscrew the fastening screw on the hook.
2. Loosen and remove the filler flap. To do this, insert a thin screwdriver through the four indents -illustration- and release the filler flap.
Releasing filler flap
3. Remove the rubber sleeve around the fuel filler neck, unscrew the two fastening screws and remove the ground cable.
Tank filler neck
4. Remove the cover under the rear seats. To do this, fold up the carpet at the markings and screw off four fastening nuts => Fuel tank openings in body.
Fuel tank openings in body
5. Left opening
5.1. Release and disconnect cable plug
Cable at left opening
6. Right opening
6.1. Release and disconnect two cable plugs -1 and 2-.
6.2. Release and disconnect the fuel line -3- at the tank.
Information
Lower the fuel tank slightly in order to release the fuel line.
6.3. Remove the fuel line -4- from the holder and release and disconnect it.
Opening on right side
7. Disconnect cable plug for fuel pump control unit.
Connector on fuel pump control unit
8. Remove cover in wheel housing at the rear right. To do this, unscrew three fastening screws -arrow- and pull off the cable holder.
Stone guard
9. Unscrew fastening screws on the filler neck and degassing tank -3-.
Filler neck
10. Remove the line bracket under the stone guard by pressing in the centre plug -arrow-.
Line bracket
11. Release and disconnect two lines -1 and 2- on the active carbon filter.
Filler neck
12. Loosen the tank attachment band, which runs in direction of travel -arrows-. Support the tank using the Master Gear unit elevating platform WE 1206.
Tank attachment band
13. Get another worker to help you to loosen and remove the remaining restraining straps. Slowly lower the fuel tank using the Master Gear unit elevating platform WE 1206. Also guide out the degassing tank in the right wheel housing.
Fuel tank mount
Installing fuel tank
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
- Note direction arrow stamped on the restraining straps and install these in the direction of travel.
Component overview of degassing tank and fuel tank in the unit
1. Lift the fuel tank using the Master Gear unit elevating platform WE 1206 and carefully guide it into position. Also guide in the degassing tank in the right wheel housing.
2. Right opening
Information
The fuel line must be connected before guiding the fuel tank fully into installation position.
2.1. Connect the fuel line -4- and lock it in the holder.
Opening on right side
3. Install plastic covers and side restraining straps. => Tightening torque: 33 Nm (24 ftlb.)
Fuel tank mount
4. Fit the tank attachment band, which runs in direction of travel -arrows-. => Tightening torque: 33 Nm (24 ftlb.)
Tank attachment band
5. Connect and lock two lines -1 and 2- on the active carbon filter.
Filler neck
6. Replace the line bracket and fit it on the longitudinal member. Clip in lines. => Line bracket
Line bracket
7. Screw in fastening screws -3- on the filler neck. => Tightening torque: 9 Nm (6.5 ftlb.)
Filler neck
8. Install cover in the wheel housing and fit cable holder. => Tightening torque: 9 Nm (6.5 ftlb.)
Stone guard
9. Connect cable plug for fuel pump control unit.
Connector on fuel pump control unit
10. Right opening
10.1. Connect two cable plugs -1 and 2-.
10.2. Connect the fuel line -3- to the fuel tank.
Opening on right side
11. Left opening
11.1. Connect cable plug.
Cable at left opening
12. Fit the cover. Then tighten the four fastening nuts => Fuel tank openings in body. => Tightening torque: 9 Nm (6.5 ftlb.) Refit the carpet and secure with double-sided adhesive tape.
Fuel tank openings in body
13. Screw in two fastening screws and fit rubber sleeve around the tank filler neck. => Tightening torque: 9 Nm (6.5 ftlb.)
Tank filler neck
14. Install the filler flap and screw in the fastening screw on the hook.
Subsequent work for fuel tank
1. Install rear seat. -> 724819 Removing and installing rear seat - section on "Installing" 724819 Removing and installing 1/3-split folding rear seat 724819 Removing and installing 2/3-split folding rear seat
2. Install underbody cover at the left and right. -> 519319 Removing and installing cover for centre underbody - section on "Installing" Service and Repair
3. Install rear wheel housing liner at the right. -> 536919 Removing and installing rear wheel housing liner Service and Repair
4. Install rear axle housing. -> 420119 Removing and installing rear axle housing - section on "Installing" 420119 Removing and installing rear axle housing
5. Disconnect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery
6. Observe warning notes. -> 2X00IN General warning notes for working on the high-voltage electrical system Procedures
7. Start the high-voltage electrical system and complete the relevant documentation. -> 2X00IN Isolating high-voltage electrical system from power supply/Starting high-voltage electrical system Procedures