16 11 030 Removing and Installing Fuel Tank (50-Liter Tank)

16 11 030 - Removing and installing fuel tank (50-liter tank)





Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.





Important!
Avoid skin contact (wear gloves)!
Ensure adequate ventilation in the place of work!
After installation of fuel tank/prior to first engine start-up:
- Check electrical resistance between metal filler bowl and wheel hub
- Measured value: approx. 0.65 W
- Fill fuel tank with at least 5 liters of fuel





Necessary preliminary tasks:
- Draw off fuel from fuel tank Procedures
- Remove rear left and right wheel arch trims
- Remove underbody panelling on left and right (R57)
- Remove exhaust system
- Remove heat shield.





Detach locking clip (1) in direction of arrow.
Disengage parking brake Bowden cable (2) from actuating lever (3) at brake caliper.
Feed out parking brake Bowden cable (2) downwards.





Release bolts (2) from rear axle carrier.

Installation:
Tightening torque 34 41 2AZ 34 41 Parking Brake.

Disengage parking brake Bowden cables from holders (1) and feed out through rear axle carrier.

Note:
Parking brake Bowden cables remain suspended on handbrake lever.





Unlock quick-release fasteners (1) on carbon canister and detach.

Installation:
Make sure quick-release fasteners engage correctly.





Release hose clamp (1) and disengage filler vent line from holder (2).

Installation:
Replace hose clip.





Release hose clamp (1) and detach filler hose from fuel tank.

Installation:
Tightening torque 16 11 4AZ 16 11 Fuel Tank and Mounting Parts.





Unlock and disconnect quick-release fastener (1) of fuel feed line.

Installation:
Make sure that quick-release fastener is correctly engaged.





Important!
Secure fuel tank over a wide area with a suitable workshop jack and secure against falling down.





Remove expander rivets (1).
Release screws (2) and lower fuel tank a little.

Installation:
Tightening torque 16 11 3AZ 16 11 Fuel Tank and Mounting Parts.

Disconnect plug connection on left sensor unit.

Important!
Vent lines on left must be guided carefully through openings in body.

Lower fuel tank.





Replacement:
- Modify left and right fuel level sensors
- Convert fuel feed line between delivery unit and cutting line
Unfasten hose clip (1) and remove hose.

Installation:
Replace hose clip.

Disconnect quick-release fasteners (2), detach vent lines (3) from bracket and modify.

Installation:
Make sure lines and wiring harness are not trapped or crushed during installation.