DIY: Fuel filter replacement / tank repair and pump replace
#1
MBWorld Fanatic!
Thread Starter
DIY: Fuel filter replacement / tank repair and pump replace
Due to not being in the USA and being able to take advantage of the warranty repair. I decided to take on the fuel tank issue myself and think I have solved a bunch of issues without spending to much.
1. Replace fuel filter in sender!
2. Repair leaking fuel tank without removing or replacing it (access ports).
3. Replace fuel pumps cheaply via rockauto.
What happens when the fuel pump or sender side leaks via cracks in either the sender or fuel pump white tops. The fuel leaks through these cracks to the outside black surface of the tank and proceeds to warp the outside sealing lip which makes the issue even worse. If you look at our tanks they are double skinned white on inside and black outside. Once fuel gets out side is when it does the damage to the tanks.
My first fix for this as copied from this forum is to fill the top of the sender and pump with jb weld so its much less likely to have the cracking failures. Second I used vice grips to carefully bend the bent opening threaded plastic of the tank back into shape so the new green seals can do their job. Third I insert a glass bowl (with TAPERED sides so it doesnt fall in the tank and the sealing rings can screw down on it) of the correct size into the opening so it holds the opening in shape overnight (I suspect wetting the area you want to move with fuel may also help...) I then refit a new jb weld filled assembly with the new green seals and it should sort the issue provided the warping on the tank opening isnt to horrific.
The fuel filter replacement is as you can see I managed to find a fuel filter (Febi Bilstein 39831) that mostly fits our senders other than one end having a hole that to small which I fixed by drilling it out to just under the suggested size of 10.7mm I drilled/reamed it to 10.5 and it seems to fit nice and snuggly. This brand fuel filter has a plastic reinforcement basket inside it so I think its much less likely to fail or begin to crush like the original filter you can see in my pics was beginning to!
1. Replace fuel filter in sender!
2. Repair leaking fuel tank without removing or replacing it (access ports).
3. Replace fuel pumps cheaply via rockauto.
What happens when the fuel pump or sender side leaks via cracks in either the sender or fuel pump white tops. The fuel leaks through these cracks to the outside black surface of the tank and proceeds to warp the outside sealing lip which makes the issue even worse. If you look at our tanks they are double skinned white on inside and black outside. Once fuel gets out side is when it does the damage to the tanks.
My first fix for this as copied from this forum is to fill the top of the sender and pump with jb weld so its much less likely to have the cracking failures. Second I used vice grips to carefully bend the bent opening threaded plastic of the tank back into shape so the new green seals can do their job. Third I insert a glass bowl (with TAPERED sides so it doesnt fall in the tank and the sealing rings can screw down on it) of the correct size into the opening so it holds the opening in shape overnight (I suspect wetting the area you want to move with fuel may also help...) I then refit a new jb weld filled assembly with the new green seals and it should sort the issue provided the warping on the tank opening isnt to horrific.
The fuel filter replacement is as you can see I managed to find a fuel filter (Febi Bilstein 39831) that mostly fits our senders other than one end having a hole that to small which I fixed by drilling it out to just under the suggested size of 10.7mm I drilled/reamed it to 10.5 and it seems to fit nice and snuggly. This brand fuel filter has a plastic reinforcement basket inside it so I think its much less likely to fail or begin to crush like the original filter you can see in my pics was beginning to!
Last edited by austingtir; 12-30-2016 at 02:15 AM.
The following 4 users liked this post by austingtir:
#2
Super Member
The USA warranty is a ten year extended warranty (I think), so we will all be in the same no warranty situation soon. I appreciate the post as this may be something I have to face someday. Does anyone know if the replacement tanks are an improved design? Is it just a matter of time before a warranty replacement tank fails? Please give us a long term follow up, I'm curious and hope this will take care of the issue for good.
#3
MBWorld Fanatic!
From talking to the tech that did my repair, it is a new part with tank and fuel pumps and filters already in. He said it was a better design. Only time will tell
#4
The USA warranty is a ten year extended warranty (I think), so we will all be in the same no warranty situation soon. I appreciate the post as this may be something I have to face someday. Does anyone know if the replacement tanks are an improved design? Is it just a matter of time before a warranty replacement tank fails? Please give us a long term follow up, I'm curious and hope this will take care of the issue for good.
#5
I just took my car into a dealer for this very issue and they said they do not honor it. I have a leaking fuel filter and who knows what else strong gas smell etc... the "service advisor" told me it only covers the gas tank itself if it cracks and that in that situation they would only replace the gas tank and none of the components attached to it... which sounds like complete bull to me. I called mbusa who is supposed to have an "executive" call me back on this issue but my experience with mercedes honoring their own warranty is that they tend to be scumbags. The dealer also charged me 180 dollars to tell me this information that I was already aware of. Any suggestions on what to do if mbusa yet again fails to honor their own warranty?
#6
Junior Member
I had a similar problem. My right side - fuel pump - was cracked and leaking up top. The first dealer I took my car to said they would not cover it. I went round n round. They said the service manager contacted MBZ and MBZ would not cover it. I pulled my car out of that dealer and called a second one. The first was closer to my house, more convenient, MY MISTAKE.... The second dealer, the dealer my shop works with and buys parts from, said no problem. I gave the service adviser my VIN over the phone, he looked it up in MBZ's database and told me it was all covered (Complete "Fuel Tank Assembly") and new the exact date the 15 extended warranty would expire. OI got them my car the next day and repair was done and returned to me in a day and a half. Key words with this complaint - "Strong fuel smell with a full tank" and "Fuel Pooling on top of the tank". The extended warranty is quite clear. Any part of the fuel tank assembly (pumps, filters, senders, seals, fuel tank etc that would have been covered under the original 4 year warranty, are covered on the 15 year extended warranty. See post #10 https://mbworld.org/forums/w211-amg/...recommend.html . Call around and be persistent!
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Dnasty (02-22-2018)
#7
Member
I just took my car into a dealer for this very issue and they said they do not honor it. I have a leaking fuel filter and who knows what else strong gas smell etc... the "service advisor" told me it only covers the gas tank itself if it cracks and that in that situation they would only replace the gas tank and none of the components attached to it... which sounds like complete bull to me. I called mbusa who is supposed to have an "executive" call me back on this issue but my experience with mercedes honoring their own warranty is that they tend to be scumbags. The dealer also charged me 180 dollars to tell me this information that I was already aware of. Any suggestions on what to do if mbusa yet again fails to honor their own warranty?
If I were you, I would go back and ask to talk to the service manager (not the service adviser), show them a copy of the bulletin, and politely ask for them to repair your car AND refund the $180 they charged you. Let them know that if they will refuse, you will be speaking to MBUSA about the issue. If they do refuse, make sure to follow through with MBUSA because they should definitely be able to help you out with this.
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Dnasty (02-22-2018)
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#8
Thanks for the info. I actually visited an out of town dealer which could be part of the issue. I contacted mbusa right after the dealer refused to repair it under warrranty and have to wait till teusday for the call back. It’s just ridiculous that these dealerships can just run like scumbags however they see fit. I actually told the service advisor I received a letter in the mail stating what is covered and the fuel filter is on it and he just had no reply then proceeded to say he ran my issue in a data base and it didn’t qualify but would love for it to be covered by Mercedes as they get paid either way. I definitely plan to pursue this 180 they took from me and file a complaint on this dealship and this clown of a service advisor. They also gave me a filthy loaner car which I had to have them rewash because I’ve never seen such despicable conditions on any rental car.
#9
Junior Member
Can be a pain. On mine the first dealer ran it as a failed fuel pump - out of warranty. In that case they are correct, a failed fuel pump is out of warranty. In your case they may have run it as a failed fuel filter or regulator - out of warranty. It's all in how they present it or write it. That's why I mentioned " Fuel Smell and Fuel Pooling". That's what the extended warranty/bulletin specifies.
I also had my letter and photos, and went in with my rear seat already removed - made it easy for them. Oh well.... Keep after it.
I also had my letter and photos, and went in with my rear seat already removed - made it easy for them. Oh well.... Keep after it.
The following users liked this post:
Dnasty (02-22-2018)
#10
Can be a pain. On mine the first dealer ran it as a failed fuel pump - out of warranty. In that case they are correct, a failed fuel pump is out of warranty. In your case they may have run it as a failed fuel filter or regulator - out of warranty. It's all in how they present it or write it. That's why I mentioned " Fuel Smell and Fuel Pooling". That's what the extended warranty/bulletin specifies.
I also had my letter and photos, and went in with my rear seat already removed - made it easy for them. Oh well.... Keep after it.
I also had my letter and photos, and went in with my rear seat already removed - made it easy for them. Oh well.... Keep after it.
A. CLIENT REPORT THERE IS A VERY STRONG FUEL
TYPE SMELL COMING INTO THE CABIN OF THE
VEHICLE,ESPECIALLY WHEN ACCELERATING OR ONCE
THE FUEL TANK HAS BEEN FILLED.CHECK AND ADVISE
X
REPLACE FUEL FILTER AND DRAIN TANK. MUST ALSO
REPLACE SEAL ON FUEL PUMP (FUEL FILTER IS
LEAKING)
Fail $1,043.00
#12
#13
Well it was as you guys said all in the wording or atleast that's what the service manager told me. They are now putting a new gas tank (and fuel filter etc.) in the car under warranty. I am not sure if the manager himself did this or my call to mbzusa caused the change in attitude because the dealership called then a couple hours later mbusa called saying they spoke with the dealership and wanted to check with me. Either way they are taking care of it as they should. Thanks for all the input guys.
#16
Thank you!
#17
MBWorld Fanatic!
#20
Member
Ohhhh sh..t
Ive replaced my filter but my plastic tube where the rubber pipe was very weak and brittle, unfortunately I snapped it while removing the clamp.
I now need a new lid for my filter basket.
The only problem is the new ones ive seen have two plugs and mine has only one. I dont really want to buy new pumps just needed a bew bloody lid!
Would the newer style lid clip on and work? As they orginal plug looks the same just i dont have a wire for the secondary (external level sensor)
God knows what to do 😢
I now need a new lid for my filter basket.
The only problem is the new ones ive seen have two plugs and mine has only one. I dont really want to buy new pumps just needed a bew bloody lid!
Would the newer style lid clip on and work? As they orginal plug looks the same just i dont have a wire for the secondary (external level sensor)
God knows what to do 😢