Procedures
WM 2010EN Draining and filling the fuel tank (draining and filling in fuel)
Tools
Technical values
Preliminary work
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
Information
- If the fuel pump is defective, the tank must be drained using the highest point.
- The tank cannot be drained reliably using the tank filler neck due to the "Spit Back" flap at the lower end of the tank filler pipe and the shape of the tank filler pipe.
- The highest point (highest flange that is always above the fuel surface) is the flange under the luggage compartment cover.
- If the tank flanges under the rear seats are opened, there is a danger of flooding the interior of the vehicle with fuel.
- If fully functional, the tank can be drained via the low-pressure transfer point above the engine torque support using an auxiliary line into a suitable container (100 litres) and the workshop tester. The Drain tank function can be selected using the Tester.
1. Remove the luggage compartment cover. -> 700619 Removing and installing luggage compartment trim (loadspace cover)
2. Pull off lid under the luggage compartment cover -1-. To do this, cut through the side connections on the sound insulation.
Cover and bodyshell openings
3. Disconnect both connections on the tank vent flange -1 and 2-. To do this, Press the push-on connectors from below using the assembly tool T10118 as required.
Tank vent connections
4. Press connecting lines aside and open the flange ring with a wrench T10202. Remove the flange ring.
5. Carefully lift up the tank vent flange, disconnect connectors -1 and 2- and remove the flange => Tank vent flange. When doing so, make sure that the fuel-level sensor -3- is not damaged.
Tank vent flange
6. Place the tank vent flange above the bodyshell opening => Positioned flange. The cable and fuel-level sensor remain fitted.
Positioned flange
Draining fuel (emptying fuel tank)
Draining fuel (emptying the fuel tank)
1. Prepare the transfer unit for draining fuel in accordance with the operating instructions provided by the manufacturer. Fuel transfer unit Tank Primus 100/100S WE 1262. Make sure to use the rounded end sleeve (prevents scratches).
2. Connect the earth cable to the vehicle. => Earth cable on vehicle
Earth cable on vehicle
Information
- Always be very careful when guiding the suction hose into the tank and make sure not to damage any interior lines and components.
- When guiding the suction hose into the tank, keep turning the suction hose and move it back and forward as required.
- Continue draining the fuel until no more fuel can be reached.
- Guide the suction hose as far as possible into each saddle.
3. Guide the suction pipe through the open flange opening at the left and right until the two tank saddles (sides of the tank) can be drained one after the other. => Sliding in suction pipe at the left and right
Sliding in suction pipe at the left and right
3.1. Continue draining each of the two tank saddles until no more fuel is comes out. Guide into both sides one after the other. => Draining tank
Draining tank
4. Remove the flanges under the rear seats if necessary and drain the remaining fuel from each saddle there.
4.1. Release the rear seat and fold it forward.
4.2. Remove bodyshell cover. -2 and 3-
Cover and bodyshell openings
4.3. Disconnect plug connections on the flanges and remove flanges using a wrench T10202. => Special tool on flange ring
Special tool on flange ring
5. Replace seals when refitting the flanges. => Seals on flanges
Seals on flanges
Subsequent work
1. Replace seals when refitting the flanges. => Seals on flanges
Seals on flanges
2. Fit the flanges using a wrench T10202. => Special tool on flange ring => Tightening torque: 110 Nm (81.5 ftlb.) and connect plug connections on flange
Special tool on flange ring
3. Fit bodyshell cover. -- Be careful of the lugs on the bodyshell cover and the cut-out on the body panel when doing this.
Cover and bodyshell openings
4. Fit luggage compartment cover. -> 700619 Removing and installing luggage compartment trim (loadspace cover)
5. Fit rear seats if necessary.
Filling with fuel (filling fuel tank)
1. Connect the filling device in accordance with operating instructions, fit the fuel nozzle and set to fuel delivery mode. Refuel the vehicle just as you would at a service station. Fuel nozzle switches off automatically.