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Remove/Install Fuel Pump - AR47.20-P-5710RF

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Engine 177, 264, 274.9, 276.8, 642, 651.9, 654.9, 656 in Model 253 

MODIFICATION NOTES

02.09.2020 Operation steps 6 and 29 added.   WS47.00-P-0039B

Shown: rear compartment on the right with fuel tank maintenance access (for Engine 651) 

G14470941Courtesy of MERCEDES-BENZ USA
G14470942Courtesy of MERCEDES-BENZ USA
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A 
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
INSPECT Check     
1 Check fuel level using vehicle diagnosis system.    
REFER TO SELF-DIAGNOSTIC SYSTEMS   NOTES The fuel tank may be filled to at most 25% before the service opening on the fuel tank is opened. AD00.00-P-2000-04B
    The fuel will finds its way into the vehicle interior otherwise.
If fuel tank is over 25% full,
↓
empty the fuel tank.		 AR47.10-P-4001RF 
REMOVING Remove     
2 Open fuel filler flap and remove fuel filler cap.    
3 Move front passenger seat to front-most position. IMPORTANT Mark position of the front passenger seat.  
4 Switch off ignition and store transmitter key outside of transmitter range (min. 2 m).    
5 Remove seat cushion in rear passenger compartment.   AR91.12-P-1020LW
6 Suction off fuel vapors from vehicle interior. Vehicles with spark-ignition Engine  
REFER TO SPECIAL TOOLS     WS47.00-P-0039B 
7 Remove maintenance cover (1).   AR47.10-P-4100-02LW 
8.1 Release and disconnect electrical connector (4). Engine 264, 274.9, 276.8, 642, 651.9, 654.9, 656 in Model 253  
8.2 Release and disconnect electrical connectors at transfer unit (7). Engine 177 in Model 253  
9 Release, remove fuel line (5) and seal openings with suitable stop plugs. Engine 642, 651.9, 654.9, 656 in Model 253
NOTES Collect exuded fuel using an absorbent rag.
Soiling will occur in the vehicle interior otherwise.
NOTES Do not kink, crush or twist fuel line (5) and do not route in tight radii.
Otherwise the fuel line (5) can be damaged.
SPECIAL TOOL Record plug		 Fig 2
10 Release, remove fuel line (3) and seal openings with suitable stop plugs. NOTES Collect exuded fuel using an absorbent rag. Soiling will occur in the vehicle interior otherwise.
NOTES Do not kink, crush or twist fuel line (3) and do not route in tight radii.
SPECIAL TOOL Fuel line (3) will otherwise be damaged. IS Record plug		 Fig 2
11 Insert claw wrench (01) in cutouts (2a) at locking ring (2), turn locking ring (2) counterclockwise. SPECIAL TOOL Claw-type wrench Fig 1
12 Mark position of locking ring (2) relative to fuel tank.    
13 Remove locking ring (2).    
14 Lift transfer unit (7). NOTES Lift transfer unit (7) only until electrical connection (6) can be disconnected. If this is not observed, damage will occur to the electrical connection (6).
NOTES Collect exuding fuel with an absorbent rag. Damage and soiling can occur in the vehicle interior otherwise.		  
15 Release and disconnect electrical connector (6). IMPORTANT Engine 177, 264, 274.9, 276.8, 642, 651.9, 654.9, 656 in Model 253 with code 916 (Fuel tank with large capacity - Volume 1)
There are two electrical connections (6).		  
16 Remove transfer unit (7) with fuel pump (M3). NOTES Collect exuding fuel with an absorbent rag. Soiling will occur in the vehicle interior otherwise.  
INSTALLING Install     
17 Clean contact surfaces of sealing ring at fuel tank and at transfer unit (7). IMPORTANT Replace sealing ring. Assembly cleaner *BR00.45-Z-1028-04A 
18 Position transfer unit (7) with fuel pump (M3) in swirl pot. NOTES Collect exuded fuel using an absorbent rag. Soiling will occur in the vehicle interior otherwise.
IMPORTANT Ensure correct seating of the fuel pump (M3) in the swirl pot.		  
19 Connect electrical connector (6) until it locks. IMPORTANT Engine 177, 264, 274.9, 276.8, 642, 651.9, 654.9, 656 in Model 253 with code 916 (Fuel tank with large capacity - Volume 1)
There are two electrical connections (6).		  
20 Position transfer unit (7) on fuel tank. IMPORTANT The molding (7a) of the transfer unit (7) must point in the direction of travel.  
21 Attach locking ring (2) in marked position and insert claw wrench (01) in cutouts (2a) at locking ring (2), tighten locking ring (2) in clockwise direction. IMPORTANT Ensure the correct engagement of the catch tab (2b) between the recesses (arrows) on the locking claws (2c).
SPECIAL TOOL Claw-type wrench		 Fig 1
22 Remove stop plugs, attach fuel line (3) and lock. NOTES Do not kink, crush, or twist the fuel line (3), and do not route in tight radii. Fuel line (3) will otherwise be damaged.
SPECIAL TOOL Record plug		 Fig 2
23 Remove stop plugs, attach fuel line (5) and lock. Engine 642, 651.9, 654.9, 656 in Model 253
NOTES Do not kink, crush or twist fuel line (5) and do not route in tight radii.
Otherwise the fuel line (5) can be damaged.
SPECIAL TOOL Record plug		 Fig 2
24.1 Connect electrical connector (4) until it locks. Engine 264, 274.9, 276.8, 642, 651.9, 654.9, 656 in Model 253  
24.2 Connect electrical connectors at transfer unit (7) until these lock. Engine 177 in Model 253  
WARNING Risk of accident  from vehicle starting off by itself when Engine running. Risk of injury (bruises and burns) resulting from working on the Engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
25 Perform Engine test run and check fuel system in area of fuel pump (M3) for leaks.    
26 Fill extracted fuel. For a tank capacity of more than 25 %. AR47.10-P-4001RF 
27 Attach fuel filler cap and close fuel filler flap.    
28 Install maintenance cover (1).   AR47.10-P-4100-02LW 
    TORQUE SPECIFICATION Screw/bolt, maintenance cover to body *BA47.10-P-1004-01P 
29 Remove the system for extracting fuel vapors Vehicles with spark-ignition Engine  
REFER TO SPECIAL TOOLS     WS47.00-P-0039B 
30 Install seat cushion in rear.   AR91.12-P-1020LW
31 Bring front passenger seat into original position.    
FUEL TANK

Number Designation Model 253
BA47.10-P-1004-01P Screw/bolt, maintenance cover to body Nm 3
Fig 1: Identifying Claw-Type Wrench (001 589 00 07 00)
G13668782Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Record Plug (129 589 00 91 00)
G13655230Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01
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