How to remove fuel tank 01Mercedes s500 w220 chassis

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Your tank is held in by metal straps with bolts against the chassis there should be a metal guard to remove first put a jaxk under tank so you can lower it slowly

Easiest way for me to help you was to printscreen the pages of mitchell of use windows paint to make .jpgs with them. Should be all you need to do it since this is the only info you will get from mercedes shop manual. Hope this helps! :)

Remove as much fuel as possible from tank. Disconnect fuel lines and fuel pump connector, remove mounting bolts holding tank to chassis, and disconnect filler tube. Lower tank down and out from under vehicle.

Instructions

• Open up the rear doors and reach in between the seam between the top of the back seat and the bottom. Unbolt the lower seat cushion from the chassis using the 3/8-inch ratchet and socket. Pull the bottom cushion away from the chassis and set it outside the vehicle.
• 2Open the gas door and remove the gas cap. Unbolt the silver fuel pump cover from the chassis using the 3/8-inch ratchet and socket. Unplug the electrical connection to the fuel pump with your hands. Put the key in the ignition and attempt to start the car. If it starts, allow it to run until the engine dies. Then remove the key from the ignition.
  
• 3
  
• Disconnect the fuel line connections to the fuel pump, using a pair of pliers. Then pull the fuel pump and bracket assembly out of the gas tank. Pull the stock seal off the gas tank with your hands. Set a replacement seal onto the tank, then install the replacement fuel pump in the tank. Reconnect the fuel lines to the fuel pump, using the pliers.
  
• 4Connect the electrical connection to the fuel pump, using your hands. Then bolt the silver cover to the chassis with the 3/8-inch ratchet and socket. Reinstall the rear seat cushion, using the ratchet
  

The fuel filter is mounted on top of the fuel tank. The fuel tubes are permanently attached to the filter.

1. Relieve the fuel system pressure.
2. Disconnect the battery ground cable.
3. Raise and safely support the vehicle.
4. Disconnect the fuel tubes from the fuel pump module and chassis fuel line.
5. Remove the filter mounting bolt.
6. Remove the filter.

To Install:

1. Install the fuel filter on the tank.
2. Apply a small amount of clean engine oil to the nipples of the fuel filter tubes.
3. Connect the fuel filter tubes to the fuel pump and chassis fuel line.
4. Lower the vehicle.
5. Connect the negative battery cable.
6. Pressurize the fuel system and check for leaks.

Fuel Tank Assembly Removal & Installation Single Tank To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section
2. Relieve fuel system pressure (See: Fuel System Relieving)
3. Disconnect the negative battery cable
4. Raise and support the vehicle
5. Drain the fuel tank in an approved container
6. Remove or disconnect the following:
   • evaporative emission (EVAP) canister Disconnect fuel lines for single tank
     
     
   • Chassis fuel lines (B) at the fuel tank (A)
     1. Cap the fuel and EVAP lines to prevent possible fuel system contamination
     Disconnect EVAP vent line
     
     
   • EVAP vent line at the fuel tank clip (E) Disconnect vent hose and filler hose
     
     
   • Vent hose and filler hose clamp (D, B)
   • Vent hose and filler hose from the line
   Fuel tank removal
   
   
7. With the aid of an assistant or a suitable jack support the fuel tank
8. Remove or disconnect the following:
   • Fuel tank strap attaching bolts
   • Fuel tank straps
9. Carefully lower the rear of the fuel tank slightly
10. Remove or disconnect the following:
    • Fuel sender cover Fuel tank connections
      
      
    • Fuel sender and the fuel pressure sensor electrical connectors
    • Fuel tank
11. Place the fuel tank in a suitable work area Fuel lines at the tank
    
    
12. Remove or disconnect the following:
    • Fuel feed and return lines (C) from the fuel sender and the retaining clips
    • Fuel pump assembly from the fuel tank
    • EVAP line from the fuel tank roll over valves (B, D) and the retaining clips (A)
    • Fuel fill hose and the vent hose from the fuel tank
    • Fuel tank

To Install:

1. Install or connect the following:
   • EVAP line to the fuel tank roll over valves and the retaining clips
   • Fuel pump assembly to the fuel tank
   • Fuel feed and return lines to the fuel sender and the retaining clips
   • Fuel fill hose and the vent hose to the fuel tank; torque hose clamps,
     1. Torque to: 22 lb-in. (2.5 Nm)
2. With the aid of an assistant or a suitable jack support and partially raise the fuel tank front end first
3. Install or connect the following:
   • Fuel sender and the fuel pressure sensor electrical connectors
   • Fuel sender cover
4. Fully raise the fuel tank
5. Install or connect the following:
   • Fuel tank straps
   • Install the fuel tank strap attaching bolts;
     1. Torque to 30 lb-ft. (40 Nm)
   • Fuel fill hose and the vent hose to the lines;
     1. Torque hose clamp to 22 lb-in. (2.5 Nm)
6. Torque the vent hose clamp,
   • Torque to: 22 lb-in. (2.5 Nm)
7. Connect the EVAP vent line to the fuel tank clip
8. Remove the caps from the fuel and EVAP lines
9. Install or connect the following:
   • chassis fuel lines at the fuel tank
   • EVAP canister
10. Lower the vehicle to the ground
11. Fill the fuel tank with clean fuel
12. Install the fuel filler cap
13. Connect the negative battery cable
14. Use the following procedure to inspect for leaks:
    • Turn the ignition on for two seconds
    • Turn the ignition off for 10 seconds
    • Turn the ignition on
    • Inspect for fuel leaks
15. Install the engine sight shield
16. Road test the vehicle to check performance

mercedes garage only ,encrypted software

The fuel filter (1) is mounted next to the fuel pump module (2), on top of the fuel tank (3)


The fuel delivery system uses quick-connect fittings. The fuel filter mounts to the top of the fuel tank.

1. Properly relieve the fuel system pressure.
   
2. Disconnect the negative battery cable.
   
3. Raise and safely support the vehicle.
   
4. Place a drain pan underneath the fuel filter to catch any spilling fuel that will result from disconnecting the fuel lines.
   

It may be necessary to support the weight of the fuel tank with a block of wood and a floor jack. Once this is accomplished, loosen, but do not remove, the fuel tank strap bolts. Allow the fuel tank to lower just enough to access the fuel line fittings at the fuel pump module.



Disengage the fuel line quick-connect fittings from the fuel pump module


Be sure to place a drain pan underneath the filter line fittings to catch all fuel spillage

Locate the fuel filter in its mounting on top of the fuel tank. Detach the quick-connect fittings from the chassis fuel supply tube and fuel pump module by squeezing the quick-connect fitting retainer tabs together and pulling the fitting assembly away from the fuel line nipple. The retainer will remain on the fuel tube.


Using a 10mm socket, remove the fuel filter mounting bolt ...


... then remove the fuel filter from the top of the fuel tank

1. Remove the fuel filter mounting bolt and remove the fuel filter from the fuel tank.
   

To install:

1. Install the fuel filter on the top of the fuel tank and tighten the mounting bolt.
   
2. The fuel supply tube (to chassis fuel line), return tube (to pump module) and fuel supply (to fuel filter) tube are permanently attached to the fuel filter. The quick-connect fitting ends of the fuel supply and return tubes are of different sizes.
   
3. Apply a light coating of 30W engine oil to the nipples of the fuel filter.
   
4. Push the quick-connect fitting over the fuel line until the retainer seats and clicks into place. Be sure the retainer tabs have locked into the case of the fitting.
   
5. If necessary, raise the fuel tank and tighten the fuel tank strap bolts.
   
6. Lower the vehicle. Start the engine and check for leaks.
   

Sounds like the Fuel sender unit in the fuel tank needs replacing however you may want to check that the electrical plugs are contacting properly,Check that the gauge is working by putting a piece of wire from the sender unit wire to the chassis,at the fuel tank sender unit plug,Turn ignition on while watching gauge if it moves toward fill turn ignition off and remove wire to chassis.If gauge moves it means from the fuel tank to fuel gauge is intact and not your problem.