Removal and Replacement
Removing and installing fuel tank
DANGER: Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.
- No fire, sparks, naked flame and smoking Pour fuels only into suitable and appropriately marked vessels. Wear protective clothing when handling fuel.
1 Drain fuel tank
NOTE: Trough fuel pump.
NOTE: If fuel pump faulty.
- Pay attention to capacity.
- Refer to Fuel Tank 2 below
2 Unscrew cap (2) and release it from fixture (4)
3 Unclip cover of left side trim panel (1)
4 Separate filler neck from guide funnel
NOTE: Open bayonet lock (3) for this step.
CAUTION: Installation: Inspect O-ring, replace if necessary. Ensure it is correctly located when installed
5 Pull filler neck through to the interior
NOTE: Screw on cap again in order to avoid fuel flowing out
6 Remove pressure sensor (B4/3)
NOTE: only USA version
7 Disconnect ground cable (X36/4) from filler neck
8 Remove spare wheel and spare wheel carrier complete
NOTE: Only on models with spare wheel on underfloor of vehicle.
9 Disconnect lines (77/2, 77/3, 77/4) at activated charcoal canister
NOTE: Activated charcoal canister and fuel tank form a single unit
CAUTION: Installation: Fit on lines according to connection diagram:
- Engine 111
- Engine 112,113
- Engine 112, 113 version (USA)
10 Remove shield of rear exhaust system
11 Unclip both rear brake cables at underfloor of vehicle and unbolt brake cable holder on right and left at frame
12 Detach rear propshaft at rear axle center section
CAUTION: Tie up propshaft e.g. with wire.
Refer to Propeller Shaft below
13 Remove trim panel at rear left of frame
14 Remove tensioning straps (80/2)
NOTE: Tensioning straps are color-coded and cannot be mixed up.
- Support fuel tank with equipment jack.
- Refer to Fuel Tank 1 below
15 Remove longitudinal strut (80/18)
Refer to Fuel Tank 1 below
16 Unbolt rear axle carrier from frame floor and lower as far as possible
NOTE: Likewise support rear axle carrier.
Refer to Rear Axle Carrier below
17 Unclip lines at side of fuel tank
CAUTION: Installation: Lines must not be damaged.
18 Separate electrical plug connection of fuel pump
NOTE: Lower fuel tank about 20 cm for this step.
19 Disconnect fuel feed line (90/12) and return flow line (90/11)
CAUTION: Fuel lines must not be kinked.
Refer to Special Tool below
20 Remove fuel tank (80)
NOTE: Guide filler neck with its chamfered side (arrow) through between frame and body. Filler neck and fuel lank cannot be separated from each other.
CAUTION: Installation: Ensure the rubber seal (5) is correctly located in the body floor.
21 Install in the reverse order
22 Dispose of fuel tank
Disposing of fuel tanks
Rear Axle Carrier:
Propeller Shaft:
Fuel Tank 1:
Fuel Tank 2:
Special Tool:
