Fuel tank installation details for all models except ML 55 AMG
Fuel tank installation details for all models except ML 55 AMG
77 - Carbon adsorber; 77/1 - Fine ventilation line connector; 77/2 - Regeneration line connector; 77/3 - Spring chamber ventilation line connector (uS models only); 77/4 - Purge line connector; 80 - Fuel tank; 80/2 - Mounting tapes; 80/18 - Longitudinal strip for tightening mounting tapes; 80/19 - Mounting bolts; 90/11 - Fuel return line; 90/12 - Fuel supply line; B4/3 - Fuel tank pressure sensor (uS models only)
1. The fuel tank installation details for all models except the ML 55 AMG are shown in the illustrations to which all references in the text refer.
2. Drain the fuel from the tank (see Section Emptying the fuel tank).
3. Unscrew the filler cap (2) and disconnect it from the safety cord (4).
4. If equipped, remove the left seat of the additional third row.
5. Remove the cover (1) from the side trim panel of the luggage compartment.
6. Disconnect the fuel lines from the expansion tank (petrol models only) and the filler neck.
7. Release the bayonet lock (3) and disconnect the filler neck from the guide socket, check the condition of the sealing ring, replace it if necessary.
8. Push the neck into the luggage compartment.
9. On US models, remove the fuel tank pressure sensor (B4/3).
10. Unbolt the grounding busbar (X36/4) of the filler neck (petrol models only).
11. Cut the cable ties securing the clamps that secure the fuel lines to the filler neck, remove the fastening clamps.
12. Drive the car onto the lift.
13. Remove the lower sealing element (5) and remove the filler neck through the luggage compartment, being careful not to damage the fuel lines.
14. Remove the left rear wheel.
15. Remove the spare wheel complete with holder.
16. Cut off the large safety bandage securing the filler neck to the bracket on the frame longitudinal beam, remove the bracket.
17. Disconnect the connectors of the regeneration (77/2) line and the purge line (77/4) of the carbon adsorber (77).
18. Disconnect the ventilation hose connected to the rear of the charcoal canister (on the rear differential assembly).
19. Remove the heat shield from the rear section of the exhaust system, being careful not to damage the drive shaft joint boots.
20. Disconnect the propeller shaft from the rear differential (see Chapter Transmission line).
21. Release the parking brake cables from the fasteners on the bottom and frame of the vehicle.
22. Unbolt the rear differential control tape from the bottom of the vehicle.
23. Remove the left anti-gravel protection deflector.
24. Remove the lower mounting straps (80/2) of the fuel tank mount and loosen the upper tension straps - the straps are marked with color marks and must be installed strictly in their original places.
25. Remove the longitudinal strip for tightening the mounting tapes (80/18).
26. If equipped, remove the headlight adjustment rod.
27. Loosen the nuts securing the lower mounts of the rear suspension shock absorbers to the wishbones (see Chapter Suspension and steering), - nuts must be replaced without fail.
28. Unbolt the rear axle holder from the bottom of the car. Support the holder and lower it as low as possible.
29. Using a jack, lower the fuel tank.
30. Disconnect the fuel pump wiring, as well as the fuel supply (90/12) and return (90/11) lines - try not to bend the fuel line tubes.
31. Remove the fuel tank assembly (80).
32. Installation is carried out in reverse order.
ML 55 AMG models
Main tank
Main fuel tank installation details for ML 55 AMG models
6 - Rear section of the exhaust system; 7 - Rubber cushions; 8 - Bolt; 9 - Nut; 10 - Clamp; 11 - Heat shield; 12 - Bolts
Main fuel tank installation details for ML 55 AMG models
13 - Fuel tank; 14 - Carbon adsorber; 15 - Filler neck; 16 - Fine Bleed Line Connector; 17 - Regeneration line connector; 18 - Purge line connector; 19 - Spring chamber purge line connector (uS models only); 20 - Mounting tapes; 21 - Longitudinal strip for tightening mounting tapes; 22 - Mounting bolts; 23 - Fuel pump wiring connector; 24 - Fuel supply line; 25 - Fuel return line; 26 - Stationary heater fuel line; B4/3 - Fuel tank pressure sensor (uS models only)
1. The installation details of the main fuel tank on ML 55 AMG models are shown in the illustrations above and in the illustration Installation details of the fuel tank on all models except ML 55 AMG, to which all references in the text apply.
2. Drain the fuel from the tank (see Section Emptying the fuel tank).
3. Unscrew the filler cap (2) and disconnect it from the safety cord (4).
4. Remove the cover (1) from the side trim panel of the luggage compartment.
5. Release the bayonet lock (3) and disconnect the filler neck (15) from the guide socket, check the condition of the sealing ring, and replace it if necessary.
6. Push the neck (15) into the luggage compartment.
7. On US models, remove the fuel tank pressure sensor (B4/3).
8. Unbolt the grounding busbar (X36/4) of the filler neck (15).
9. Remove the rear section of the exhaust system (6).
10. Loosen the screws (12) and remove the heat shield (11)
11. Remove the additional fuel tank.
12. Disconnect the lines (16, 17, 18 and 19) from the carbon adsorber (14).
13. Release the parking brake cables from the fasteners on the bottom and frame of the vehicle.
14. Disconnect the propeller shaft from the rear differential (see Chapter Transmission line).
15. Remove the left rear frame trim panel.
16. Remove the mounting straps (20) securing the fuel tank - the straps are marked with color marks and must be installed strictly in their original places.
17. Remove the longitudinal strip for tightening the mounting tapes (21).
18. Support with a jack, unbolt from the floor frame and lower the rear axle carrier assembly as low as possible.
19. Release the lines from the holders on the walls of the fuel tank.
20. Disconnect the fuel pump wiring, as well as the fuel supply (24) and return (25) lines and the fuel line (26) of the stationary heater - try not to bend the fuel line tubes.
21. Disconnect the fuel pump wiring (23).
22. Lower the fuel tank assembly (13) and remove it from under the vehicle, making sure that the filler neck does not catch on the vehicle frame or body.
Attention! Separating the neck from the tank is not possible!
23. Installation is carried out in reverse order.
Additional tank
Additional fuel tank installation details for ML 55 AMG models
1 - Rear section of the exhaust system; 2 - Right rubber cushion; 3 - Left rubber cushion; 4 - Bolt; 5 - Nut; 6 - Fastening clamp; 7 - Heat shield; 8 - Bolts; 9 - Mounting tapes; 10 - Screws; 11 - Support bracket; 12 - Bolts; 13 - Bolts
Additional fuel tank installation details for ML 55 AMG models
Fuel tank installation details for all models except ML 55 AMG
1. The installation details of the main fuel tank on the ML 55 AMG models are shown in the illustrations to which all references in the text refer.
2. Empty the fuel tank (see Section Emptying the fuel tank).
3. Remove the rear section of the muffler (1).
4. Remove the heat shield (7).
5. Disconnect the fuel lines (14 and 15) from the additional fuel tank (17).
6. Loosen the bolts (10) and remove the mounting straps (9) securing the additional tank (17).
7. Unscrew the bolts (12), loosen the bolts (13) and fold down the support bracket (11).
8. Disconnect the vent line (18) from the top of the tank and move it to the side.
9. Remove the auxiliary fuel tank assembly (17).
10. Installation is carried out in the reverse order - if necessary, replace the clamps (16) securing the fuel hoses (14 and 15), try not to damage the ventilation line (18).