Replacement Procedure

WARNING:
PERFORM THE FUEL TANK REPLACEMENT PROCEDURE IN A WELL VENTILATED AREA. DO NOT SMOKE OR PERMIT OTHERS TO SMOKE IN THE GENERAL AREA WHERE THE FUEL TANK REPLACEMENT PROCEDURE IS BEING PERFORMED. DO NOT PERFORM THE FUEL TANK REPLACEMENT PROCEDURE NEAR AREAS WHERE SPARKS OR OPEN FLAMES COULD BE PRESENT FAILURE TO COMPLY WITH THESE SAFETY REQUIREMENTS CAN LEAD TO SERIOUS BODILY HARM AND PROPERTY DAMAGE.

NOTE:
In addition to standard hand tools and shop equipment, obtain the following materials before proceeding with the replacement procedure:

- Fuel Tank Replacement Kit (Part Number MB927507)
- 1992 Expo/Expo LRV Service Manual, Volume 1





1. Release fuel pressure in the high pressure side of the fuel system by disconnecting the fuel pump connector and its rubber grommet.

Start the engine, and let it run until it stops. After the engine stops, turn the ignition off, reconnect the fuel pump connector, and reposition the rubber grommet.





2. Disconnect the battery's negative terminal.

3. With a suitable container situated below, drain the fuel from the main tank and sub tank by removing the two drain plugs.








4. Remove the propeller shaft from the vehicle. Refer to the service manual excerpt on page 4 for removal information.

NOTE:
Before removal, be sure to paint a mating mark on the propeller shaft flange to allow for proper re-installation.





5. Remove the fuel tank from the vehicle. Refer to the service manual excerpt for a diagram of the removal sequence.

Excerpt from page 13-198 of the 1992 Expo/Expo LRV Service Manual:

6. With the old and new fuel tanks side-by-side, transfer all parts not contained in the fuel tank replacement kit from the old tank to the new tank.

The re-used parts include the fuel pump, fuel gauge, fuel lines, and any other parts attached to the fuel tank that are not in the replacement kit.

7. Attach the replacement kit parts to the new tank.

CAUTION:
Remove and discard the two plates covering the fuel pump and fuel gauge unit openings. These plates are used for dust protection during shipping and handling. If the sealing material surrounding the two openings is damaged, replace it prior to fuel pump and fuel gauge unit installation.

8. Install the new fuel tank on the vehicle.

NOTE:
Before connecting fuel hoses and fuel vapor hoses, make sure all hose ends are clean and undamaged.

9. Connect fuel hoses, fuel vapor hoses, and all other fuel tank components and connections.

10. Reconnect the battery's negative terminal.

11. Refuel the vehicle, start the engine, and check for fuel and vapor leaks. If any leaks are found, tighten the suspected fitting and recheck until no leaks are present.





12. Install the propeller shaft on the vehicle. Refer to the service manual excerpt on page for installation instructions.