Remove/install fuel pump and fuel tank sensor - AR47.20-P-7000GZ

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ENGINE 113, 156, 272, 273, 629, 642 in MODEL 164

Shown on model 164.1

Fig 1: Identifying Fuel Pump And Fuel Tank Sensor Components - Shown On Model 164.1

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Modification notes

4.8.06

"Disconnect ground line" has been removed

	Remove/install
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel.	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
1	Remove fuel tank	Model 164.8	AR47.10-P-4100GZ
	Only perform operation steps 2 to 6 for model 164.1
2	Pump or suction off fuel out of right-hand chamber of fuel tank	Engine 113, 156, 272, 273
		If fuel pump is intact:	AR47.10-P-4001GZ
	If fuel pump is defective:		AR47.10-P-4000GZ
		Pump or suction off about 20 liters if fuel tank is full.
3	Fold rear seat cushion forward
4	Raise sound deadening mat and place to one side out of working area
5	Remove cap on the right (1) at marked separation point (2) and remove	Installation: Replace cap on the right (1) and insert with new sealing mass. The right cap (1) is glued in with body sealer. Heat with hot air gun to make it easier to remove.
		White sealing compound, 310 ml, DBL 6069.20	*BR00.45-Z-1003-01A
6	Disconnect electrical connector (3)
7	Use pronged wrench to unscrew on ring nut (4)	Installation: The parts kit with ring nut (4), sealing ring and threaded ring (8) must be replaced.
		Ring nut to fuel tank	*BA47.10-P-1004-01J
		Prong wrench	Fig 2
8	Disconnect electrical connector (6) and remove mounting cap (5)
9	Disconnect fuel feed line, fuel return line and level line (7) from fuel pump with fuel level sensor (M3/3)	Level line is used for adjusting fuel level of both halves of tank.
10	Remove swirl pot and fuel pump with fuel level sensor (M3/3)
11	Install in the reverse order
12	Connect STAR DIAGNOSIS, read and erase diagnostic trouble code memory		AD00.00-P-2000-04A
	Checking
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
13	Carry out engine test run and check fuel system for leaks

FUEL TANK

Number	Designation		Model 164.1/8
BA47.10-P-1004-01J	Ring nut to fuel tank	Nm	110

Fig 2: Identifying Claw-Type Wrench (164 589 01 07 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20