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Remove/install tank recess - AR88.60-P-2000EW

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MODEL 204.3, 207, 212, 218 

Shown on model 212.0 

Fig 1: Tank Recess Remove/Install Components - Shown On Model 212.0
G09977934Courtesy of MERCEDES-BENZ USA

Shown on model 218.9 

Fig 2: Tank Recess Remove/Install Components - Shown On Model 218.9
G09977935Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A
1 Raise vehicle with vehicle lift
2 Loosen rear fender paneling (9) from bumper down to below tank recess (1) and lift out of rear fender and bumper using assembly wedge SPECIAL TOOL Mounting wedge Figure
3 Remove trim strip (12) MODEL 218.9
NOTES
For this purpose open rear door and carefully push trim strip (12) toward front (in direction of rear-end door).
Otherwise the trim strip (12) can bend or the vehicle paint damaged
IMPORTANT Check clips (13) for damage, replace if necessary.		  
4 Remove drain hose (10) from tank recess (1)    
5 Unlock fuel filler flap (5) on catch hook (arrow A) and remove from hinge (4)    
6 Remove expansion clip (3)    
7 Remove rubber plug (2)    
8 Turn central locking bolt guide (7) 90° and remove    
9 Disengage catch hook (1.1) behind release hole (arrow E) with extraction hook (8) and simultaneously pull hinge (4). Then perform procedure on release hole (arrow D, arrow B and arrow C) IMPORTANTSPECIAL TOOL Insert extraction hook (8) into release hole (arrows B to F) only until catch hooks (1.1) can be disengaged.  
SPECIAL TOOL Extraction hook Figure
10 Coat sealing lip on tank recess (1) with lubricant and install over tank flap NOTES
Carefully put sealing lip on tank recess (1) over tank cap.
Otherwise the sealing lip can tear.		  
Lubricant, rubber assembly 1 l *BR00.45-Z-1010-06A 
11 Remove tank recess (1)    
INSTALLING Install     
12 Install rubber plug (2) in tank recess (1)    
13 Coat sealing lip on tank recess (1) with liquid lubricant and clip tank recess (1) into rear fender NOTES
Carefully put sealing lip on tank recess (1) over tank cap.
Otherwise the sealing lip can tear.		  
Lubricant, rubber assembly 1 l *BR00.45-Z-1010-06A 
14 Insert central locking bolt guide (7) and turn 90°    
15 Install expansion clip (3)    
16 Install fuel filler flap (5) on hinge (4)    
17 Guide rubber seal (11) over connection fittings on drain hose (10) IMPORTANT Ensure that rubber seal (11) is seated correctly.  
18 Clip in trim strip (12) MODEL 218.9
NOTES
Carefully clip in trim strip (12).
Otherwise trim strip (12) can be bent.
IMPORTANT If necessary, remove clips (13) remaining in trim strip (12) from trim strip (12) and install at corresponding point on vehicle. Previously check clips (13) for damage, replace if necessary.		  
19 Install drain hose (10) on connection fitting    
20 Fasten rear fender paneling (9)    
21 Lower vehicle with vehicle lift    
Fig 3: Identifying Mounting Wedge (110 589 03 59 00)
G09977936Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Extraction Hook (140 589 02 33 00)
G09977937Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
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