Removing Fuel Tank

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Do not smoke, eat or drink in the work area.

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

→ Never leave the carbon canister hanging freely on the lines.

→ A second person must hold the carbon canister during removal.

Information 

• Absorb any escaping fuel using a suitable binding material or a cloth  .
• Cloths which have absorbed fuel must be disposed of according to the applicable national laws  .
• The fuel system must be depressurized before starting work on it  .
• Only work on the fuel system in well-ventilated rooms  .
• Any seals which have been removed must always be replaced  .
• Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors  .

Information 

For safety reasons, the fuel tank should only be removed and installed when empty. → 200317 DRAINING AND FILLING FUEL 

Fig 1: Overview Of Degassing Tank And Fuel Tank

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Fig 2: Overview Of Fuel Tank (Diesel - Single-Pump System)

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1. Fuel filler neck
2. Fuel tank
3. Left cap
4. Locking ring
5. Left fuel level sensor
6. Sucking jet pump, left
7. Protective cover
8. Restraining strap
9. Fastening screw
10. Protective cover
11. Left sucking jet pump (on tank floor)
12. Fuel pump (delivery unit)
13. Right fuel level sensor
14. Protective cover
15. Right cap

1. Open the filler flap and unscrew the fastening screw on the hook.
2. Loosen and remove the filler flap. To do this, insert a thin screwdriver through the four indents -illustration-  and release the filler flap.
   Fig 3: Releasing Filler Flap

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3. Remove the rubber sleeve around the fuel filler neck, unscrew the two fastening screws and remove the ground cable.
   Fig 4: Removing Rubber Sleeve

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4. Remove the cover under the rear seats. To do this, fold up the carpet at the markings and screw off four fastening nuts → Fuel tank openings in body  .
   Fig 5: Identifying Fuel Tank Covers

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5. Left opening
   1. 5.1. Release and disconnect cable plug
      Fig 6: Disconnecting Cable Plug

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6. Right opening
   1. 6.1. Release and disconnect two cable plugs -1 and 2-  .
   2. 6.2. Release and disconnect the fuel line -3-  at the tank.

      Information 

      Lower the fuel tank slightly in order to release the fuel line.

   3. 6.3. Remove the fuel line -4-  from the holder and release and disconnect it.
      Fig 7: Identifying Fuel Line And Cable Plugs

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7. Disconnect cable plug for fuel pump control unit.
   Fig 8: Disconnecting Cable Plug For Fuel Pump Control Unit

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8. Remove cover in wheel housing at the rear right. To do this, unscrew three fastening screws -arrow-  and pull off the cable holder.
   Fig 9: Locating Stone Guard

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9. Unscrew fastening screws on the filler neck and degassing tank -3-  .
   Fig 10: Identifying Filler Neck And Degassing Tank Screws

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10. Remove the line bracket under the stone guard by pressing in the center plug -arrow-  .
    Fig 11: Identifying Line Bracket

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11. Release and disconnect two lines -1 and 2-  on the active carbon filter.
    Fig 12: Identifying Lines

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12. Loosen the tank attachment band, which runs in direction of travel -arrows-  . Support the tank using the Master Gear Unit Elevating Platform WE 1206  .
    Fig 13: Locating Tank Attachment Band

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13. Get another worker to help you to loosen and remove the remaining restraining straps. Slowly lower the fuel tank using the Master Gear Unit Elevating Platform WE 1206  . Also guide out the degassing tank in the right wheel housing.
    Fig 14: Identifying Fuel Tank Mounting Components

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    No.	Designation	Qty.	Removal	Installation
    	Fuel Tank	1	Do not damage fuel tank and connected lines. Lines cannot be replaced individually.	Do not damage fuel tank and connected lines. Lines cannot be replaced individually.
    -2-	Restraining Strap, Front Left	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.
    -3-	Fastening Screw, M8 x 25	10
    -4-	Plastic Covers, Left	2
    -5-	Plastic Cover, Right	1
    -6-	Restraining Strap, Rear Right	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.
    -7-	Restraining Strap, Front Right	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.
    -8-	Restraining Strap, Center	1		The direction of travel arrow must be pointing forward.
    -9-	Restraining Strap, Rear Left	1	Before releasing the restraining straps, make sure that the tank cannot fall down.	The direction of travel arrow must be pointing forward.

14. Slowly lower the fuel tank using the transmission jack and carefully guide in the degassing tank in the right wheel housing.
    Fig 15: Identifying Tank On Jack

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