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

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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:

Extract FUEL from fuel tank
Remove REAR SEAT BENCH .
Remove rear right WHEEL ARCH PANEL .
Remove PROPELLER SHAFT .
Remove COMPRESSION STRUT on left and right.
Remove UNDERBODY PANELLING , rear left and right.

Fold floor trim (1) to one side.

Unscrew nuts (2).

Remove cover for service opening (3).

Fig 1: Identifying Floor Trim Panels, Service Opening And Nuts

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Disconnect plug connection (1).

Disconnect fuel lines (2).

If necessary, disconnect fuel line for auxiliary heating.

Installation note:

Check gasket (3), replace if necessary.

Fig 2: Identifying Fuel Lines, Plug Connection And Gasket

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Unclip line clip (1).

Release plastic nut (2).

Installation note:

Check plastic nut (2), replace if necessary.

Tightening torque: 16 12 2AZ .

Fig 3: Identifying Fuel Filler Pipe Line Holder And Plastic Nut

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Release quick-release coupling (1).

Fig 4: Identifying Quick-Release Coupling

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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 .

Detach fuel filler pipe (2) from fuel tank.

Fig 5: Identifying Fuel Filler Hose Clamp

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IMPORTANT: Secure fuel tank against slipping and falling out.

Heavily support the fuel tank.

Fig 6: Supporting Fuel Tank

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Unfasten nut.

Installation note:

Replace self-locking nut.

Tightening torque: 16 11 1AZ .

Fig 7: Locating Self-Locking Nut

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Undo nuts and bolts (1).

Installation note:

Tightening torque: 16 11 2AZ .

Lower fuel tank.

Fig 8: Identifying Fuel Tank And Bolts

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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:

Modify fuel pump . See 16 14 200 REMOVING AND INSTALLING OR REPLACING FUEL PUMP .