Gas tank — removal and installation (Mercedes-Benz C-Class W201)

Warning: This operation must be carried out in a well-ventilated area.

Removal

1. Before starting work, empty the gas tank. This is best done after waiting until almost all the gasoline has been used up as a result of normal operation. The remainder should be sucked out through the filler neck by siphoning or using a hand pump.

2. Place the vehicle on a level surface and place chocks under the front wheels. Raise the rear of the vehicle with a jack and securely support it on jack stands (see Fig. "Lifting the car with a jack and placing it on supports").

Warning: It is not recommended to use an inspection pit; gasoline vapors are heavier than air and can easily collect on the floor of a pit, creating a potential hazard.

3. Disconnect the negative battery terminal.

4. Working from underneath the vehicle, disconnect the fuel inlet and outlet lines and the vent hose from the fuel tank. Mark the hoses so that they can be reinstalled correctly. Plug any open holes in the fuel tank and hoses to reduce fuel spillage and prevent dirt from getting into the fuel system.

5. Remove the large rubber grommet from the gas tank.

6. Working from the trunk, unfasten the holders and move the carpet back. Unfasten the buttons and holders, then remove the fuel filler panel (see Fig. 6.6, a, b).





7. Referring to the description in Chapter 4, disconnect the plug from the fuel level sensor unit connector. Release the wire from the holders.



8. Loosen the fuel tank mounting nuts, lift the fuel tank slightly and remove the drain hose. Remember how the drain hose is routed so you can install it the same way. Separate the filler neck from the body and remove the sealing ring (a) and sleeves (see fig. 6.8).



9. Lift the gas tank up, pull it back towards you and remove the gas tank from the luggage compartment. Remove the padding strips if they are not secured.

10. Unscrew the mesh filter from the fuel tank and remove the sealing ring. Using clean gasoline, remove all traces of deposits. Using a new sealing ring, install and tighten the mesh filter securely.

11. If you find sediment or water in the fuel tank, remove the fuel gauge sender as described in paragraph 5, and rinse the tank with a small amount of clean gasoline.

If the gas tank is significantly corroded or leaking, it should either be repaired by a professional or replaced.

Warning: Do not attempt to repair the gas tank yourself by welding or soldering. The gas tank may contain an explosive mixture of air and gasoline vapor.

Installation

12. Install the gas tank in reverse order. Please note the following:

• a) Where provided, tighten all fasteners to the required torque.
• b) Check that the packing strips are installed correctly.
• c) Check that the fuel tank drain hose is routed as it was before removal.
• d) Check that the sensor plug is securely connected to the socket.
• d) Perform a test drive and make sure that there are no gasoline leaks around the removed parts.