Removal and Replacement

Fuel tank

Special tools:
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

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.

Removal

Removing the exhaust system
Detach the exhaust system at the three-way catalytic converter (TWC) and at the rubber mountings.
Hang the exhaust system to one side.

Note! Support the front section of the exhaust pipe so as not to put strain on the exhaust manifold.

Removing the heat deflector plate





Remove:
- the 7 plastic nuts
- the heat deflector plate.

Detaching the hose connections





Remove:
- the hose clamp for the evacuation pipe at the fuel tank
- the hose clamp for the hose to the fuel filler pipe.

Note! Carefully detach the hose from the fuel filler pipe, there may be fuel left in the tank.

Removing the carbon filter container





Remove:
- the hose (1)
- the 2 pipes, secured using quick-release connectors (2).

Removing the fuel tank




Install a mobile jack with fixture 999 5972 FIXTURE 999 5972 Fixture under the fuel tank.
Disconnect the fuel connection (1).
Remove the screws for the fuel tank straps, x 3.
Remove the tank retaining straps. Lower the tank slightly.
Disconnect the level sensor connector.
Lower the tank.

Removing the fuel pump (FP)

Remove:
- the fuel connection for the fuel pump (FP)
- the fuel pump (FP). See: Fuel pump and level sensor unit, B5254T7, AW55-50/51SN, B5254T7, M66 Service and Repair.

Installation

Installing the fuel pump (FP)

Install:
- the fuel pump (FP). See: Fuel pump and level sensor unit, B5254T7, AW55-50/51SN, B5254T7, M66 Service and Repair.
- the fuel connection for the fuel pump (FP).

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.
Connect the connector for the level sensor.
Lift up the fuel tank.

Install:
- the tank retaining straps. Use the 3 x M8 screws
- the fuel connection.

Installing the hose connectors

Install:
- the hose clamp for the evacuation pipe at the fuel tank
- the hose clamp on the hose for the fuel filler pipe.

Installing the carbon filter container





Install:
- the hose
- the 2 pipes, secured using quick-release connectors.

Installing the heat deflector plate

Install:
- the 7 plastic nuts
- the heat deflector plate.

Installing the exhaust system

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Removal and Replacement.

Install:
- the exhaust system. Use the 2 x M10 nuts
- the rubber mountings.

Finishing

Top up the fuel.
Install the fuse for the fuel pump (FP).