Removal and Replacement
Fuel tank
Special tools:
951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)
999 5972 FIXTURE 999 5972 Fixture
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Draining the fuel system
Drain the fuel system. See: Fuel system pressure release, B5254T7 Fuel System Pressure Release.
Drain the fuel tank. See: Fuel tank draining Service and Repair.
Removing diagonal stays
Remove on both sides:
- the 3 x screws
- the diagonal stays under the subframe.
Removing the exhaust system
Remove:
- 2 x nuts for the front exhaust pipe
- the screw (1) for the cross member
- remove the screws (2) and place the cross member to one side
- the rubber mounting for the front exhaust pipe
- the 2 x rubber mountings for the rear muffler
Removing the air baffle left-hand side
Remove:
- the 2 x plastic nuts (1)
- the screw (2)
- the air baffle.
Removing the shock absorber
Hint: Position a mobile jack under the lateral link and raise slightly.
Remove on both sides:
- the bolt, x1
- the shock absorber from the lateral link.
Lowering the sub-frame
Note! Ensure that no cables / hoses are put under strain or are trapped when lowering the sub-frame.
Position the mobile jack against the sub-frame.
Pull the brake hose out of its bracket on both sides.
Remove:
- the screws on both sides
- the 2 x screws on both sides.
Lower the sub-frame approximately 5 cm. Ensure that no cables / hoses are put under strain or trapped when lowering the sub-frame.
Removing the rear heat deflector plate
Remove:
- the 5 plastic nuts.
- the heat deflector plate.
Removal
Removing the fuel tank
Remove:
- the quick release connector for the fuel line under the tank. Use: 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)
- the fuel filler pipe.
Note! Carefully detach the hose from the fuel filler pipe. There may be fuel left in the tank.
Remove the pipes with quick-release connectors, x 2.
Apply a mobile jack with fixture: 999 5972 FIXTURE 999 5972 Fixture under the fuel tank.
Remove:
- the 3 x screws for the tank strap
- the tank strap. Lower the tank slightly.
- the connector for the level sensor
- the fuel tank
- the quick-release connector for the fuel line.
Transferring components
Note! Transfer the fuel pump (FP) to the new fuel tank. See: Fuel pump and level sensor unit, B5254T7, AW55-50/51SN, B5254T7, M66 Service and Repair.
Installation
Note! For tightening torques, see Specifications. Tightening Torque.
Installing the fuel tank
Place the tank on the mobile jack together with fixture: 999 5972 FIXTURE 999 5972 Fixture.
Raise the tank so that it is 30 cm from the top.
Install:
- the connector to the level sensor
- the fuel line.
Lift up the fuel tank.
Install:
- the tank retaining straps. Use the 3 x M8 screws
- the pipes and quick-release connectors from the carbon filter container for the tank, x 2
- the fuel filler pipe
- the fuel line under the tank.
Finishing
Installing the rear heat deflector plate
Install:
- the heat deflector plate
- the 5 x plastic nuts.
Installing the sub-frame
Note! Ensure that no cables / hoses are loaded or trapped when installing the sub-frame.
Lift up the sub-frame. Ensure that the locating pins engage in their holes in the bodywork.
Install the 2 x screws on both sides. Tighten. See: Tightening torque [1][2]Specifications
Install:
- the screw on both sides. Tighten. See: Tightening torque [1][2]Specifications.
Remove the lifting table.
- the brake hose in its bracket on both sides.
Installing the shock absorber
Raise the lateral link slightly.
Install on both sides:
- the shock absorber
- the screw. Tighten. See: Tightening torque [1][2]Specifications
Installing the exhaust system
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Install:
- the exhaust system using the new flange package
- the 2 x M10 nuts
- the rubber mountings
- the 2 M8 screws.
Installing the air baffle left-hand
Install:
- the air baffle
- the 2 x plastic nuts (1)
- the screw (2).
Installing diagonal stays
Install on both sides:
- the diagonal stays
- the M12 screws, 3 pcs. Tighten acc.. to Tightening torque [1][2]Specifications.
Topping up fuel
Top up the fuel.
Install the fuse for the fuel pump (FP).