Genuine Mercedes-Benz C240 Fuel Tank

Mercedes-Benz C240 Fuel Tank Parts and Q&A

• Fuel Tank
  203-470-92-01
  Q: How to remove and install the fuel tank on Mercedes-Benz C240?

  A:

  Relieve the fuel system pressure, then disconnect the cable from the negative battery terminal. Remove the rear seat cushion and the access panels for the fuel level sensor and Fuel Pump/fuel level sensor module, followed by the removal of the retaining rings for both modules. Working through the access hole for the fuel level sensor, disconnect the electrical connector from the sensor assembly. Lift up the fuel level sensor from the left side of the fuel tank and siphon out as much fuel as possible, then do the same for the fuel pump/fuel level sensor from the right side. Loosen the rear wheel bolts, raise the vehicle securely on jackstands, and remove the rear wheels. Detach the two under covers by removing the nuts from the front and rear, then pull the cover straight down. Remove the entire rear exhaust system from the flange in front of the pre-muffler to the muffler/tailpipe, then remove the retaining nuts that secure the exhaust pipe heat shields and take off the heat shields. Detach the driveshaft from the rear differential flange, then remove the parking brake cable cover and disconnect the parking brake cables from the equalizer, pulling the cables out of the cable bracket. If equipped, disconnect the rear brake pad wear sensors from the calipers, trace the sensor leads, and disengage them from any clips on the rear suspension assembly before unbolting and removing the rear brake calipers, supporting them with lengths of wire. Remove the rear stabilizer bar and locate the electrical terminal for the rear wheel speed sensor leads in the underside of the vehicle body, disconnecting the two wheel speed sensor leads from the terminal. Remove the coil springs and support the rear suspension assembly with an adjustable-head transmission jack, ensuring the crossmember is securely supported on each side. Remove the four large bolts that attach the rear suspension crossmembers and carefully lower the rear suspension assembly. Remove the splash shield from the right rear wheel well, then loosen the hose clamps for the fuel filler neck hose, fuel overflow shutoff hose, and fuel tank vent hoses, disconnecting all three. Support the fuel tank, remove the fuel tank strap nuts, and detach the fuel tank straps. Lower the tank slightly and disconnect any remaining electrical harnesses and EVAP hoses before lowering and removing the fuel tank. For installation, reverse the removal process, ensuring to transfer all components from the old fuel tank to the new one if replacing it, tighten the fuel tank strap nuts securely, and adjust the parking brake cables when finished.