Mercedes-Benz Truck 2000-05

Removal & Installation

Print

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure and drain the fuel tank.
  4.  
  5. Remove the tank cap and unhook it from the tank cover holder.
  6.  
  7. Remove the left seat from the 3rd row, then remove the cover from the left side paneling.
  8.  
  9. Detach the fuel lines from the expansion reservoir on the fuel filler neck.
  10.  
  11. Open the bayonet lock and disconnect the filler neck from the guide funnel. During installation, be sure to replace the O-ring; the lock should be located above the pressure sensor.
  12.  
  13. Install the fuel cap and pull the filler neck through to the interior.
  14.  
  15. Detach the electrical connector, then remove the fuel tank pressure sensor from the side of the filler neck.
  16.  
  17. Remove the ground connectors from the fuel tank filler neck.
  18.  
  19. Cut into the cable strap of the retaining clip for the fuel lines on the filler neck and remove the retaining clip.
  20.  
  21. Raise and safely support the vehicle. Be sure to lift it high enough that will allow lowering of the rear axle and removal of the fuel tank.
  22.  
  23. Disconnect the rubber seal on the filler neck from underneath the vehicle then pull the filler neck out.
  24.  
  25. Remove the left rear wheel and the spare tire, including the carrier.
  26.  
  27. Cut into the large securing cable band for the filler neck on the holder on the longitudinal frame member, then remove the holder.
  28.  
  29. Label and detach the hoses from the charcoal canister.
  30.  
  31. Remove the rear exhaust system shield.
  32.  
  33. Matchmark the position of the driveshaft on the rear axle flange. Remove the bolts, then secure the driveshaft out of the way. Discard the bolts, as new ones must be used during installation.
  34.  
  35. Unclip the rear brake cable on the underfloor, then remove the cable holder at the frame.
  36.  
  37. If equipped, detach the rear axle check strap and headlight level regulation linkage from the axle.
  38.  
  39. Remove the rear left stone chip guard.
  40.  
  41. Support the fuel tank with a transmission jack, then remove the fuel tank tensioning straps.
  42.  
  43. Remove the nuts from the lower shock absorber mount on the control arm.
  44.  
  45. Support the rear axle carrier, then detach the axle housing from the frame and lower it as far as possible with out damaging any components to allow removal of the fuel tank.
  46.  
  47. Lower the fuel tank, then detach the lines and electrical connections from the fuel tank. Remove the tank from the vehicle.
  48.  
  49. Installation is the reverse of removal. Tighten the fuel tank check straps to 15 ft. lbs. (20 Nm). Refer to the appropriate procedures in this section for the tightening specifications of other components.

    Click image to see an enlarged view

    Fig. Detail of the fuel filler neck components



    Click image to see an enlarged view

    Fig. Exploded view of the fuel tank mounting

  50.  

 
label.common.footer.alt.autozoneLogo