Removal and installation of fuel tank

Torque wrench, double-arm, 15-63 Nm

00 589 27 21 00

Self made tool — model 126

Conventional, offset box-end wrench (SW 19}, length according to drawing

When removing fuel tank, pay attention to safety rules.

1    Disconnect grounding line on battery.

2   Drain fuel tank. Carefully pump out fuel, so that no residual fuel remains in fuel tank.

47.2 llb-700/1 F2

3 Loosen suction hose, fuel return hose and vent hose. Catch residual fuel from hoses. Close hoses and connections.

Model 107, 116, 123 Suction hose

Model 107.02

Vent and return flow hose

Model 116, 123.03/05 Vent and return flow hose

Model 123.09

69  Suction hose

70  Return flow hose

47.2 llb-700/2 F2

4 On T-sedan, remove luggage compartment floor and intermediate compartment. Pull off vent hoses (arrows) and coupling (66).

Model 123.09

5 Loosen hose clamp (arrow) and pull off vent hose. Close hose and pipe connection.

Model 123.09 Vent hose

Model 126

69  Suction hose

70  Return flow hose

Model 126 64 Vent hose

47.2 llb-70073 F2

Model 126 QjJ

51 Vent valve 64 Vent hose 72 Sealing sleeve

6    Remove luggage compartment mat.

7    Unscrew rear wall and remove.

8   On model 107.04, remove fuel expansion tank (1) (47-705).

Model 107.04

1     Fuel expansion tank

2    Fuel hoses

3    Fuel tank Arrow = Vent line

47.2 llb-700/4 F2

9   Unscrew fastening nuts.

10   Slightly pull out fuel tank and pull off coupling for fuel readout on immersion tube transmitter.

11    Remove fuel tank.

1 Coupling immersion tube transmitter Arrows = Fastening nuts

Note: On T-sedans, for removing fuel tank remove protective casing for pump assembly. Then unscrew the three fastening screws (arrows) for combination holder pump assembly/fuel tank. Disconnect harness for fuel pump at edge of fuel tank.

Model 123.09

12 Install fuel tank in vice versa sequence, proceed as follows:

a) Glue both gaskets to bottom of fuel tank by means of MB universal glue, part No. 000 989 92 71. For installation, coat both gaskets on sealing surface or bead with sliding compound (talcum, wax or the like).

Model 107.02/123

1   Positive and negative vent line

2   Return flow line

Model 116

1   Positive and negative vent line

2   Return flow line

147- 16744

47.2 llb-700/5 F2

b)  Check whether foam rubber strip on fuel tank is rigidly attached and glue down with MB universal glue, part No. 009 989 02 71, if required.

c)  On model 123.09, glue foam rubber strips on fuel tank at level of filler neck crosswise to driving direction.

Note: Never use felt or similar material, since otherwise corrosion damage may occur.

d)  Blow out strainer (b) and check for damage. Renew sealing ring (a). Install fuel strainer (68) and tighten to 35-43 Nm.

Note: The strainer jacket (b) comprises a square mesh fabric with 0.1 mm mesh width. To prevent mixups, the word “Benzin” (gasoline) is printed on metal section.

e)   Install fuel tank with specified reinforcing sheet metal and washers. Tighten fastening nuts to 17—25 Nm.

On model 123.09, tighten self-locking fastening nuts to 26-34 Nm.

f)   Install vent hose (arrow) between fuel tank and filler neck free of kinks and with a continuous slope toward fuel tank.

The slipped-on O-ring serves for sealing at passage toward interior.

g)  Pay attention to correct seat of sleeves on filler neck.

Model 123.09

47.2 llb-700/6 F2

h) On model 123, check seal between fuel tank and rear floor and seal again, if required. For this purpose, carefully apply Unionzement by means of a brush or the like against circumference of opening (arrows).

i) Check fuel hoses and renew, if required.

j) On model 126, renew copper seal between fuel tank and return flow hose (70).

Model 126

k) For installing expansion tank on model 107.04, install vent line behind filler neck first.

I) When tightening hose clamps, apply counterhold to connections of expansion tank.

m)Plug on protective sleeve at end of vent line.

1   Fuel expansion tank

2   Fuel hoses

3   Fuel tank Large arrow = Vent line

47.2 llb-700/7 F2

n) Check function of fuel readout (ground connection on battery connected).

o) Check fuel system for leaks.

On these vehicles a guide funnel (1) is installed in filler neck to accommodate the small fuelling guns for lead-free fuel.

If a fuel tank on these vehicles is renewed, simultane­ously install a guide funnel in USA vehicles only. For this purpose, prior to assembly of fuel tank, insert guide funnel into filler neck and knock in fastening rivet (1) up to stop by means of a mandrel.

47.2 lib-700/8 F2

Fuel tank positive and negative venting lines

Model 107.04

13     Hose clamps

31     Protective sleeve

32     Vent line

34     Fuel tank

35    Sealing ring

36     Immersion tube transmitter

38    Closing cap

39     Seal

40     Rubber grommet

45     Expansion tank

46     Fuel hose

47     Fuel hose

47.2 llb-700/9 F2

47.2 llb-700/10 F2

47.2 lib—700/11 F2

50 Fuel tank

50a Reinforcing sheet metal

50b Washer

50c Nut, self-locking

55 Expansion tank

T-sedan and 2nd version

Special vehicles with special body

55a Expansion tank 1st version

Special vehicles with special body

60     Filler neck

60a   Sealing sleeve (2 each)

62     Closing cap

62a   Sealing ring

64     Vent lines 64a   Vent line 64b  Sealing ring

65     Immersion tube transmitter 65a   Sealing ring

68     Fuel strainer 68a   Sealing ring

69     Feed

70     Return flow

73     Vent sleeve 2nd version

73a   Protective sleeve 1st version

47.2 llb-700/12 F2

47.2 llb-700/13 F2