![]() Fuel will remain in the assembly as you remove it, so do your best to pour as much out as you can before you pull it out. Push down on the button and push the third hose towards the connection before pulling it out to disconnect it.Ĭarefully pull the assembly out of the tank. Two of the hoses will pull out of the assembly. Next, disconnect the three hoses and the one remaining harness plug from the assembly. Disconnect the electrical connection from the top piece and then remove it from the tank. Then, pull the fuel pump assembly out of the tank, partway.Īs you pull up the assembly, it’ll want to separate into two pieces. Spread the locking ring and pull it off of the fuel pump assembly. Use a flathead screwdriver to pry on the clamp to help remove it. Use a 7mm socket to loosen the clamp enough to remove it. Then, head over to the fuel pump unit and remove the clamp from the locking ring. Let the car run until it shuts off, then head back to the sending units and unplug all connections to the level sending unit. To do so, disconnect the electrical plug from the top of the fuel pump unit and start the car. You’ll need to relieve the fuel pressure before removing anything from the tank. ![]() Step 2: Remove the fuel level sending unit Remove the six bolts from the tan cover adjacent to the black cover to expose the fuel pump housing. Use an 8mm socket to remove the six cover bolts. The level sending unit mounts to the tank under the black circular cover on the driver’s side of the seat base. Pull the seat bottom away from the seat back and then out of the car. Then use a 13mm socket to remove the nuts. First, pop the plastic covers off of the seat bottom mounting nuts. The fuel filter and level sending unit sit beneath the rear seat. Steps required to replace the fuel level sender in a Mercedes W203: Step 1: Gain access to the fuel level sender CTA Fuel Tank Lock Ring Tool (optional).Tools required to replace the fuel level sender in a Mercedes W203: Parts required to replace the fuel level sender in a Mercedes W203: Clean any of this off before opening the fuel tank to keep the fuel free of any contamination. The top of the tank may contain dirt and debris. Seat aside an hour or two to give yourself adequate time to complete the repairs yourself. You may have to wrestle with some brittle plastics, but nothing major needs to be done beyond that. The fuel pump assembly and fuel level sending unit are easily accessible under the rear seat. How long will it take to replace the fuel level sender in a Mercedes W203? For peace of mind, you could replace that as well. While you’re performing this DIY, you’ll access the fuel pump. That includes a new lock ring for the level sending unit and the new seals and clamps. It will cost around $365 to purchase all of the components listed below. We recommend replacing all of the plastic components around the fuel level sender to avoid cracking issues. Fuel vapor is especially tough on the plastic components it touches, causing them to become brittle. The W203 Mercedes C-class is almost two decades old now. How much will it cost to replace the fuel level sender in a Mercedes W203? Anyone of the electrical connections or the level sending arm can become compromised from the possible corrosion. Ethanol in our current fuel will corrode metals in the fuel tank. There are more possible causes for incorrect reading, but the sending unit is where you should start. Combined with the evap emission codes, the fuel smell should point you to the top of the fuel tank.Īn incorrectly reading fuel level gauge can also point you in the direction of the fuel level sending unit. If you can smell the gasoline inside of the car, the chances are that something has cracked around the top of the fuel tank. If you’re lucky, a fuel smell will exist inside the cabin. Evap emission codes can be tricky to pin down but, depending on the code, will point you in the gas tank’s direction. The fuel level assembly is mounted into the fuel tank’s top to read the fuel present and house the required sensors to read the fuel tank’s pressure. Symptoms of a bad fuel level sender on a Mercedes W203: However, this DIY is relevant to anyone with a W203 C350 as well as most W209 models. The fuel level sending unit listed below and demonstrated in this video only fits the vehicles listed above.
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