Fuel Pump: Service and Repair

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

Shown On Model 203.035 With Engine 111.951:

Remove/Install

DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
- No fire, sparks, naked flames or smoking.
- Wear acid-resistant gloves, clothing and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery

CAUTION: Model 209: Do not connect quiescent current retention unit, otherwise damage may occur in the control module.

DANGER:
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.
- No fire, sparks, naked flames or smoking.
- Pour fuels only into suitable and appropriately marked containers.
- Wear protective clothing when handling fuel.

2 Pump fuel out of the right-hand chamber of

NOTE:
- Suction off approx. 20 liters if fuel tank is the fuel tank full:
- Draining and filling fuel tank.
- Pay attention to fuel quantity.

- Fuel tank capacity, Total capacity = 62 Liters
Reserve capacity = 8 Liters

3 Fold rear seat cushion (1) forward
4 Unscrew retaining straps (2) of the rear seat cushions (1)
5 Fold back floor covering (3)
6 Remove right end cover (4)
7 Use pronged wrench to unscrew ring nut (5)
- Claw-type wrench: See Special Tools below.
- Ring nut to fuel tank = 85 Nm

8 Remove locating cover (6) with shaped seal (7)

NOTE: Installation: replace sectional sealing ring (7).

9 Detach plug connection (8) on fuel level sensor, right half of tank (B4/2)
10 Disconnect feed line (9) at fuel pump (M3)

NOTE: The fuel level sensor, right half of tank, (B4/2) and the fuel pump (M3) form a single unit.

CAUTION: Installation: Replace O-ring of feed line (9), in order to avoid fuel escaping.

11 Pull fuel level sensor, right half of tank (B4/2) out a little
12 Disconnect return line (10) at fuel level sensor, right half of tank (B4/2)
13 Remove fuel level sensor, right half of tank, (B4/2) together with fuel pump (M3)
- Installation: Check the three supports at the floor of the fuel level sensor, right half of tank (B4/2) for damage, if necessary exchange fuel level sensor, right half of tank (B4/2) with fuel pump (M3).

NOTE:
- Marking on the locating cover (6) must be aligned with the marking on the tank.
- Do not exchange fuel pump (M3) individually, only in connection with fuel level sensor, right half of tank (B4/2).
- If any of the three supports is damaged, proper attachment of the fuel level sensor, right half of tank, is no longer assured. B4/2

14 Install in the reverse order

Special Tools

Prong Wrench, P/N # 203 589 01 07 00: