Fuel Systems
Removing and installing fuel tankA. Removing and installing guide funnel (on all models with catalytic emissions control system)
Remove guide funnel (10)
Special Tool 123 589 05 33 00:
To do this, pull out the two rivets (arrows) with special tool 123 589 05 33 00.
Caution: Do not permit rivets to drop into fuel tank. They cancel the function of the splash bowl (fuel reserve quantity cannot be used).
Note: A guide funnel (10) is installed because of the smaller fuel dispensing nozzle for unleaded fuel. When replacing the fuel tank, a guide funnel must be installed.
Note: Models 107, 124, 126, 201 National version -USA. The guide funnel is provided with additional notches (arrows) to facilitate installation.
Production Breakpoints:
B. Model 124 Sedan
Warning: Pay attention to safety precautions. Risk of accident!
Disconnect battery ground cable
Release pressure in fuel tank by removing cap (40)
Check seal (41), replace if necessary.
Remove fuel gauge sender (B4). Only if exchanging fuel tank.
Drain fuel tank (50). Carefully pump out fuel so that no further fuel remains in the tank. Capacity approx. 70 liters.
Remove cup seal (60/1)
Remove fuel tank trim and also left and right trunk side trim
Take off fuel feed line (69), fuel return line (70), vent line (64/1), vent valve (51)
Note: Collect remaining fuel. Seal connections. Check suitability for reuse. Ensure cup seals (80, 81) are correctly seated. Tightening torque 28 Nm (reference value).
Screw nuts (50/4, 4 ea.)
Installation note: Use washers (50/2). Tightening torque 20 Nm (reference value).
Take fuel tank (50) out
Installation note: Stick sound proving strips with MB universal adhesive 000 989 92 71 if necessary.
Remove fuel strainer (68). Clean and check suitability for reuse. Tightening torque 40 Nm.
Replace seal (68/1)
Briefly run engine, check connections for leaks.
Notes: Model 124
Vent line (aluminium version) is plastic coated. Except national version AUS, J, USA
Improved sealing of the splash ball in fuel tank by means of an O-ring. This avoids misfiring (in long right hand curves and the fuel tank less than "1/4 full"). Identification: green colored dot on bottom of filler neck.
C. Model 124 Station Wagon
Warning: Pay attention to safety precautions. Risk of accident!
Disconnect ground cable at battery
Release pressure in fuel tank by removing cap (40)
Check seal (41) check, replace if necessary.
Remove fuel gauge sender (B4). Only if exchanging fuel tank.
Drain fuel tank (50). Carefully pump out fuel so that no fuel remains in the tank. Capacity approx. 72 liters.
Remove cup seals (60/1)
Remove vent line (64/2)
Installation note: Pre-install vent line at fuel tank. Lay line with slight rise and free of kinks. Check that cup seal (64/3) is correctly seated.
Detach Fuel feed line (69), fuel return line (70), leak line (72) detach, fit on.
Note: Collect remaining fuel. Seal connecUons. Check suitability for reuse.
Detach Vent valve (51)
Detach Exhaust system at rear suspension point. Detach with V-belt.
Remove Splash guard (58) filler neck.
Remove Level line holder (left side).
Remove U rail (56), attachment (50/2, 50/4, 50/5). Tightening torque 30 Nm. Use self-locking nuts (50/4).
Caution: Support fuel tank when performing this step.
Remove fuel tank (50).
Caution: When removing fuel tank, ensure that the connection fitting for the vent line (64/2, at the filler neck) does not catch on a line. Push exhaust pipe and level line to the left.
Installation note: Stick sound proving strips between rear floor and fuel tank with MB universal adhesive 000 989 92 71
Remove Fuel strainer (68), clean and check suitability for reuse. Tightening torque 40 Nm.
Replace Seal (68/1)
Run Engine briefly.
Check connections for leaks.