Installing Fuel Tank

Installing Fuel Tank







Required tools

Item 1 - 3:

Installing fuel tank

NOTE:
- The repair procedure may vary depending on engine type and country equipment. This relates in particular to components in the right wheel housing.
- The description relates to ORVR vehicles.
- Sealing rings must generally be replaced.

The following exploded drawing shows the attachment of the fuel filler neck and carbon canister in the right wheel housing.

No. 1 - 7:

The following exploded drawing shows how the fuel tank is attached to the vehicle floor.

No. 1 - 9:

WARNING:
Danger of fire.
- Keep clear of ignition sources.
- Do not smoke.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO(2) or dry powder fire extinguishers.

CAUTION:
- Observe general warning notes and working regulations.
- For safety reasons, the tank should only be removed and installed when empty

NOTE:
- The top left cover must be fitted before the tank is installed.
- When installing the tank and rear axle, make sure that cables and lines are not damaged and are in the correct installation position.
- When introducing the tank into the body, a second person should guide the degassing tank and safeguard it against damage using wire.

1. Raise the tank with a transmission jack. Make sure to secure the tank with a tension strap to prevent it from falling.







2. Place tank in installation position. A second person should guide the degassing tank.

NOTE: Note direction arrow stamped on the restraining straps and install these in the direction of travel.

3. Attach lower covers and fit the four restraining straps, which run at right angles to the direction of travel. Make sure that the stamped arrow is pointing forwards in the direction of travel. Tighten the fastening screws (M8 x 25) to 23 Nm (17 ftlb.). Secure filler neck and degassing tank again with wire-arrow-.

Figure shows secured degassing tank (shown here with carbon canister attached)







4. Lower the transmission jack and fit the centre restraining strap. The arrow must be pointing forwards. Tighten the fastening screws (M8 x 25) to 23 Nm (17 ftlb.).







5. Fit the exhaust system heat shield. If the shield is cracked or damaged, it must be replaced. Tighten the three sheetmetal nuts and the two screws.







6. Fit the underbody cover at the left and right of the side members.

NOTE: When fitting the suspension subframe, guide the hand brake cable through and place in installation position. Do not damage lines and cables.

7. Install suspension subframe. Guide hand brake cable through the suspension subframe and place in installation position.







8. Replace the four suspension subframe screws (M14 x 135). Tightening torque: 120 Nm (89 ftlb.) + 180 degrees torque angle.







9. Attach front right rear axle transmission ventilation tube to the rear axle.







10. Screw in the four fastening screws (M12 x 80) of the top damper housing to 90 Nm (67 ftlb.) and 120 degrees torque angle. Fastening screws must be replaced.

Figure shows vehicle with air suspension







11. Connect the electric plugs-2-at the rear left and then clip the rubber sleeve -1-into the sheetmetal holder.







12. Connect the electric plug -1-at the rear right and then clip the rubber sleeve-2-into the sheetmetal holder.







NOTE:
- For vehicles with air suspension, the compressed air line on the spring strut must also be connected. Tightening torque: 3 Nm (2 ftlb.)







- The electrical plug connection of the height sensor must be connected in vehicles with air suspension or automatic headlight beam adjustment.







13. Replace internal serration screws on the brake calipers. Tighten the rear brake calipers on the left and right of the wheel bearing housing to 180 Nm (133 ftlb.) -2-. Connect cable plug of the brake pad wear indicator -1-.







14. Insert hand brake cable into the rear brakes.
15. Carefully press on the sheetmetal clips of the hand brake cable on the fuel tank.







16. Install rear cardan shaft.
17. Pull cardan shaft joints away from one another so that they sit in the transmission flanges.
18. Position six screws-arrow-onthe centre holder but do not tighten them.







19. Position cardan shaft again on the markings -arrow- which were made on the distributor and rear axle transmission before removal.

Transfer box flange marking







Rear axle transmission marking







NOTE:
- To attach the cardan shaft on the rear axle transmission a second fitter should counter the triangular flange of the transfer box.







- Screws which are tightened with a torque angle must be replaced with new ones.

20. Tighten new screws for cardan shaft flange on the rear axle transmission to 30 Nm (22 ftlb.) + 90 degrees torque angle.
21. Tighten bolts on the cardan shaft triangular flange to transfer box to 75 Nm (56 ftlb.). Counter with an open-ended wrench.







22. Tighten centre bearing holder of cardan shaft to body to 60 Nm (44 ftlb.).







NOTE: Center bearing must be installed without tension. Therefore unscrew and tighten centre bearing bolts on holder -arrow-.







23. Unscrew centre bearing bolts on holder -arrow- so that the bearing is relaxed and then tighten to 20 Nm (15 ftlb.).

NOTE: Replace exhaust clamps on exhaust system.

24. Lift exhaust system onto the transmission jack and secure with a tension belt. Replace exhaust clamps and push onto exhaust pipe.

Figure shows exhaust system on transmission jack







25. Place exhaust system in installation position.
26. Screw the fastening screws on the left and right of the rear silencer to 23 Nm (17 ftlb.).







27. Fit the front and middle holders. To do so, tighten the two fastening screws to 23 Nm (17 ftlb.).







28. Then slide the new exhaust clamps into installation position and fix them into place. The bolts must be pointing downwards. Maximum inclination: 10 degrees. Tightening torque: 60 Nm (44 ftlb.).







29. Replace line holder and attach to side member. Clip in lines.







30. Then, fit the stone shield on the right side. Tighten the screws -2- to 10 Nm (7.5 ftlb.).







31. Replace the ground cable tie-wraps on the carbon canister and pre-assemble the ground cable. Lift the carbon canister into the wheel well.
32. Join all lines on the carbon canister and degassing tank at the plug connections.

NOTE: The rubber hose-2-of the leak diagnosis pump may have to be replaced in USA vehicles.

33. Carefully attach the two electric plugs -3- on the carbon canister and on the leak diagnosis pump and the hose on the filler neck -2 -of the leak diagnosis pump (USA). Replace the hose, if necessary. Then, connect plastic line -1-.







34. Insert the hose on the degassing tank.







35. Tighten the five fastening screws on the carbon canister and the two on the degassing tank in the right wheel housing to 10 Nm (7.5 ftlb.) -arrows-.







36. Install rear right wheel housing liner.







37. Fit rear wheels and tighten to 160 Nm (118 ftlb.).
38. Connect ground cable to filler neck. Tighten the two fastening screws (M6 x 20) to 10 Nm (7.5 ftlb.) and fit the rubber sleeve around the fuel filler neck.







39. Fit the fuel supply -1-at the connection unit and attach the two disconnection points -2 and 3-.







40. Fit lids. Tighten the four fastening nuts to 10 Nm (7.5 ftlb.). Refit carpeted floor and fix with double-sided adhesive tape.







41. Tighten the belt anchor fastening plates. Use three new fastening screws for this and tighten to 20 Nm (15 ftlb.).







42. Fold rear seat down again.
43. Reconnect the battery.
44. Activate air suspension and fill using PST.
45. Refuel the tank and screw the tank cap on tightly.
46. Align rear axle.


Tightening torques