Fuel Systems
Removing and installing fuel tankA. Removing and installing guide funnel (on all models with catalytic emissions control system)
Remove guide funnel (10)
Special Tool 123 589 05 33 00:
To do this, pull out the two rivets (arrows) with special tool 123 589 05 33 00.
Caution: Do not permit rivets to drop into fuel tank. They cancel the function of the splash bowl (fuel reserve quantity cannot be used).
Note: A guide funnel (10) is installed because of the smaller fuel dispensing nozzle for unleaded fuel. When replacing the fuel tank, a guide funnel must be installed.
Note: Models 107, 124, 126, 201 National version -USA. The guide funnel is provided with additional notches (arrows) to facilitate installation.
Production Breakpoints:
Warning: Pay attention to safety precautions. Risk of accident!
Disconnect ground cable disconnect at battery
Release pressure in fuel tank by removing cap (40).
Check seal (41), replace if necessary.
Remove fuel gauge sender (B4). Only if exchanging fuel tank.
Drain fuel tank (50). Carefully pump out fuel so that no fuel remains in the tank. Capacity approx. 90 liters.
Remove cup seal (60/1).
Remove trunk/fuel tank partition.
Remove fuel feed line (69), fuel return line (70), vent valve (51).
Note: Use shortened ring wrench (shop made tool) for fuel return line.
Seal connections. Check suitability for reuse.
Check that cup seals (80, 81) are correctly seated. Tightening torque 28 Nm (reference value)
Screw down nuts (50/4, 4 ea.)
Installation note: Use shims (50/2). Tightening torque 20 Nm (reference value)
Remove fuel tank (50)
Installation note: Stick sound proofing strip (74) with MB universal adhesive 000 989 92 71 if necessary. Install reinforcing plates (50/1) with reinforced side between bracket and fuel tank.
Remove fuel strainer (68), clean and check for suitability for reuse Tightening torque 40 Nm (reference value)
Replace seal (68/1)
Briefly run engine, check connections for leaks.