Fuel Pump - Modified Mounting Brackets
86mercedes01TO: OUR MERCEDES-BENZ PASSENGER CAR DEALERS
DATE: May 1986 REF.NO.. 07.3/38
SUBJECT: MODIFIED FUEL PUMP PACKAGE MOUNTING BRACKET AND LARGER DIAMETER FUEL PUMP MODEL 201.024/034
FIGURE 1 - MODIFIED FUEL PUMP PACKAGE MOUTING BRACKET:
As of July 1985, modified mounting brackets using rubber rings to attach the fuel pump package are installed on the above vehicles, similar to model 124. On model 201.024 a fuel pump measuring 60 mm in diameter (previously having measured 52 mm in diameter) is additionally installed.
Effective Serial Number
Model Chassis End No.
201.024 1A 236576
1F 132824
201.034 1F 132831
FIGURE 2 - TEMPLATE (SHOP-MADE):
The modified brackets can also be installed on vehicles built prior to the chassis-end numbers listed on page 1. In this case, a template must be made to ensure that the brackets are correctly attached to the underbody.
NOTE: When installing the modified bracket, it is not necessary to replace the 52 mm dia. fuel pump.
FIGURE 3 - FUEL PUMP AND BRACKET:
Procedure
1. Unscrew and remove protective cover.
2. Pinch section of fuel intake hose between fuel tank and fuel pump with special clamp 000 589 40 37 00.
3. Cut the fuel intake hose from fuel tank at the crimped sleeve in front of the T-fitting and shorten the insulating hose.
4. Remove fuel pump package with vibration damper.
5. Unscrew fuel suction hose from fuel filter.
6. Screw template onto existing rear fuel pump bracket on underbody, sure that they are aligned with one another.
7. Drill four holes with a 3 mm diameter. Then remove template.
8. Bore out rivet heads of previous brackets with an 8 mm drill and remove brackets.
9. Attach new brackets (item 1, Figure 3) to underbody with B 6.3 x 16 sheet metal screws in the holes drilled in step 7. Before tightening the screws, insert rubber rings and insert two B6 washers between the bracket and underbody on the right-hand side (in the direction of travel) of the front and rear brackets.
10. Modify fuel pump package on workbench. Remove fuel accumulator, filter and pump from the existing assembly bracket. Loosely assemble the two halves of the new bracket (2) and install the fuel pump package in the following order:
10.1 Install fuel reservoir (14) so that it rests against the stop.
10.2 Insert fuel filter (21) and pump (M3) using spacer sleeves (3 and 4). Turn the split ends of the sleeves so they face each other and cannot move in the bracket. The fuel pump spacer sleeve is required only when reinstalling the 52 mm diameter pump.
10.3 Screw fuel line (5) onto fuel accumulator (14) and to the fuel filter and pump.
10.4 Finish tightening the fuel pump bracket screws.
11. Attach suction intake and pressure hose bracket (6) to fuel pump package.
12. Install fuel hoses (7 and 8).
13. Install fuel pump package with the rubber rings to the underbody.
14. Route fuel hoses connected to the fuel pump package so that they are free from any chafing.
15. Connect intake hose using a 21 mm diameter hose clamp and remove pinch clamp attached in step 2.
16. Connect electric wiring. Start engine and check for any leaks.
17. Mark and drill 3 mm dia. holes for protective cover screws. Install new protective cover (10) on underbody using B6.3 x 16 sheet metal screws.
Parts Information
Quantity Part Name Part Number
1 Steel fuel line 201 470 19 64
1 Fuel pressure line from fuel filter to feed line 201 470 37 75
1 Fuel hose with T-fitting and leak line to fuel 201 470 39 75
reservoir
1 Rubber grommet 100 997 08 81
1 Bracket for fuel pump package 124 470 02 81
2 Brackets on underbody 124 478 02 40
4 Rubber rings 124 478 00 82
1 Bracket for fuel hoses 201 478 48 40
1 Spacer sleeve for fuel pump 124 478 03 53
1 Spacer sleeve for fuel filter 124 478 04 53
1 Protective cover 201 478 04 37
4 Copper sealing rings, 12 mm dia. 007603 012102
7 Sheet metal screws B 6.3 x 16 007983 002200
3 Washers B6 000125 006421
2 Hose clamps, 21 mm dia. 916033 021100
1 Hose clamp, 11 mm dia. 916033 011100
1 Bolt AM 5 x 10 DIN 7985/4.8 007985 005125
1 Bolt AM 5 x 20 DIN 7985/4.8 007985 005149
1 Bolt AM 5 x 35 DIN 7985/4.8 007985 005151
Time Allowance
02-2211/41/44 Fuel Pump Bracket Modification 1.7 hrs.
02-0212/41/44 Fuel Pump Bracket Modification 1.4 hrs.
(with Maint. or Repair Work)