16 11 030 Removing and installing/replacing fuel tank (N57)

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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: Ensure adequate ventilation in the place of work!
Avoid skin contact (wear gloves)!
After installation of fuel tank/prior to first engine start-up:

Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection.
Fill fuel tank with at least 5 liters of fuel.

Necessary preliminary tasks:

Draw off FUEL from fuel tank
Remove REAR SEAT
Remove rear right WHEEL ARCH TRIM
Remove PROPELLER SHAFT
Remove TENSION STRUT on left and right

Fold both floor covers (1) to the side.

Unfasten screws (2).

Remove cover for service opening (3).

Fig 1: Identifying Floor Cover And Screws

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Disconnect plug connection (1).

Disconnect fuel lines (2).

Installation:

Check seal (3), replace if necessary.

Fig 2: Identifying Fuel Lines And Plug Connection

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Vehicles with auxiliary heating:

Disconnect plug connection (1).

Disconnect fuel lines (2).

Installation:

Check seal (3), replace if necessary.

Fig 3: Identifying Fuel Lines And Plug Connection

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Release plastic nut (1).

Installation:

Check plastic nut (1), replace if necessary.

Tightening torque 16 12 2AZ .

Unclip line holder (2).

Fig 4: Identifying Plastic Nut And Hexagon Nut

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IMPORTANT: There may be residual amounts of fuel in the tank!
Catch escaping fuel in a suitable container.

Unfasten hose clip (1).

Installation:

Check hose clamp, replace if necessary.

Tightening torque 16 12 1AZ .

Fig 5: Identifying Hose Clamp

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Remove fuel filler pipe.

Unscrew nuts (1).

Installation:

Tightening torque 16 11 1AZ .

Fig 6: Identifying Fuel Tank Mounting Screws

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IMPORTANT: Secure fuel tank against slipping and falling out.

Heavily support the fuel tank.

Fig 7: Supporting Fuel Tank

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Release screws (1).

Installation:

Tightening torque 16 11 2AZ .

Lower fuel tank.

Fig 8: Identifying Lower Fuel Tank And Screws

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If necessary, disconnect fuel line for independent heating.

Remove fuel tank.

Replacement:

Convert FUEL PUMP
Convert TANK FILL LEVEL SENSOR