Instructions
Chassis / Fuel Tank / Fuel Service Procedures / DA-RM-04K001-00-001 - Drain/Fill fuel tank
Preparation work
1.     
2.     
3.     
4.     
Care Point: Remove the left side only.
5.     
6.     
Care Point: Remove the left side only.

WARNING!
 
Risk of explosion, poisoning and injury working with fuel!
Fuels are highly flammable and toxic if inhaled. Fuel vapours are explosive, invisible and spread out at floor level. This vapour is poisonous when inhaled and has an anesthetizing effect in high concentrations. Fuel can cause damage to skin. For example, skin is degreased when it comes into contact with gasoline fuel.
Observe the national safety precautions and regulations.
Keep fuel away from fire, open light or ignition sources.
Ensure the work place is adequately ventilated.
Never drain or pour in fuels over assembly pits.
Store drained fuel in a suitable and sealed vessel.
Immediately eliminate any fuel which has flowed out.
Conducting work on a vehicle with open flames (e. g. welding etc.).
Before carrying out this work, remove relevant parts of fuel system and seal open fuel lines with plugs.
 

WARNING!
 
Possible fluid spills from vehicle systems during repairs or maintenance.
Risk of thermal incidents, slip hazards, corrosion of electrical components, failure of electrical or mechanical components or unwanted odours.
Always limit fluid spills and fully clean the spilled fluid after repairs or maintenance.
 

Drain fuel tank
1.  
Record the fuel level before you do this procedure.
 

 
Care Point:
Fuel can spill. Always wear the correct Personal Protective Equipment (PPE).

 
2.  
Disconnect the fuel filler hose (1).
 

 
Care Point:
Use a fuel extractor tool with a suitable container.
Risk of contamination. Make sure that the tool is clean.

Care Point:
A non-return valve is installed in the filler port on the fuel tank. You must not damage the non-return valve.
Make sure that no adaptors are attached to the fuel extractor hose.

 
3.  
Carefully push the fuel extractor hose into the fuel tank (2).
 
4.  
Operate the fuel extractor tool to remove the fuel.
 
 
Care Point:
Risk of damage. Do not use too much force when you remove the fuel extractor hose.

 
5.  
Carefully remove the fuel extractor hose.
 
6.  
If you cannot easily remove the fuel extractor hose:
1. Push the fuel extractor hose in a small distance.
2. Rotate the fuel extractor hose.
3. Try to remove the fuel extractor hose again.
 
7.  
Some fuel will stay in the fuel tank. If you replace the fuel tank, make sure that you drain the remaining fuel.
 


Fill fuel tank
1.  
Install the components in reverse order.
 
2.  
Fill the fuel tank to the level that you recorded.
 

   
   
   Note