16 11 030 Removing and installing/replacing fuel tank (S63)

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Recycling

Fuel escapes when fuel lines are detached. Have a suitable collecting vessel ready.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

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

Check earth 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 BENCH
Remove rear right WHEEL ARCH PANEL
Remove PROPELLER SHAFT
Remove COMPRESSION STRUT on left and right

Fold both floor trims (1) to the side.

Unfasten screws (2).

Remove cover for service opening (3).

Fig 1: Identifying Floor Cover And Screws

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Release lock (1) in direction of arrow.

Pull off fuel line (2).

Disconnect plug connection (3).

If necessary, disconnect fuel line for auxiliary heating.

Installation note:

Make sure the fuel line engages correctly.

Fig 2: Identifying Fuel Line And Plug Connections

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Release plastic nut (1).

Installation note:

Check plastic nut (1), replace if necessary.

Tightening torque 16 12 2AZ .

Unclip line clip (2).

Release quick-release coupling (3).

Fig 3: Identifying Quick-Release Coupling And Line Clip

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

Unfasten hose clamp (1).

Installation note:

Check hose clamp, replace if necessary.

Tightening torque 16 12 1AZ .

Fig 4: Identifying Hose Clamp

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Remove fuel filler pipe from fuel tank.

IMPORTANT: Secure fuel tank against slipping and falling out.

Heavily support the fuel tank.

Fig 5: Supporting Fuel Tank

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Release screws (1) and remove tensioning straps (2).

Installation note:

Replace screws.

Tightening torque 16 11 2AZ .

Lower fuel tank.

Fig 6: Identifying Tensioning Straps And Screws

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IMPORTANT: The metal fuel tank (1) has a middle centering element!
During installation the fuel tank must be aligned with the aid of dimension (A) on the left and right centrally to the body!
Dimension (A) must be identical on the left and right sides!

Fig 7: Identifying Fuel Tank Dimension On Left And Right To Body

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If necessary, disconnect fuel line for independent heating.

Feed fuel tank ventilation line through opening in body.

Remove fuel tank.

Replacement:

Convert FUEL PUMP .
Modify fuel level sensor