Sprinter Van Fuel Pump: Diy Replacement And Repair Guide

The fuel pump in a Mercedes Sprinter van is located inside the fuel tank and is responsible for delivering fuel from the tank to the engine. Over time, heavy wear and tear can cause issues with the fuel pump, leading to reduced performance or even complete engine failure. Some common signs of a faulty fuel pump include unexpected engine stalls, difficulty starting the engine, reduced power, increased fuel consumption, and a loud whining noise. Replacing the fuel pump typically involves disconnecting the battery, draining the fuel pump, removing the pump assembly, and installing a new one. While it is possible to replace the fuel pump yourself, it is recommended to seek professional assistance due to the risk of fire.

Disconnect the battery

Disconnecting the battery is one of the first steps to take when changing the fuel pump on a Mercedes-Benz Sprinter van. This is a crucial safety precaution to reduce the chance of a fire when working on the fuel system.

To disconnect the battery, first, locate the negative battery cable. This is usually a black cable with a negative (-) symbol. It is attached to the battery terminal, which is typically located on the battery's top or side. Once you have located the negative battery cable, proceed to carefully disconnect it. Use caution and wear protective gear, as the battery contains sulfuric acid and can produce explosive gases.

It is important to note that disconnecting the battery may cause the vehicle's computer to lose certain settings, such as radio presets or clock settings. If possible, make a note of these settings before proceeding. Additionally, ensure that you have the radio security code, as you may need to enter it after reconnecting the battery.

After disconnecting the negative battery cable, securely cover the terminal with a piece of tape or a battery terminal protector to prevent accidental contact or arcing. This will provide an extra layer of safety while you work on the fuel pump replacement.

Once the battery is disconnected and the terminal is covered, you can proceed to the next steps of accessing the fuel pump and performing the replacement. Remember to exercise caution and follow safety protocols throughout the entire process.

Remove rear seating

To access and replace the fuel pump in your Mercedes-Benz Sprinter van, you will need to remove the rear seating to reach the integrated floor access cover. Here is a step-by-step guide on how to remove the rear seating:

Step 1: Gather Your Tools

Before you begin, make sure you have the necessary tools for the job. You will need a socket wrench and a set of screwdrivers, including a flathead and a Torx screwdriver. It is also recommended to wear safety goggles and gloves for your protection.

Step 2: Prepare the Vehicle

Park your vehicle on a level surface and engage the parking brake. Ensure that the engine is turned off and the keys are removed from the ignition. If your van has a double passenger seat, you may need to unbolt the centre seat belt mounting, which can be accessed through the seat cushion. This will allow the whole seat to tilt forward.

Step 3: Remove the Rear Seat Cushion

Locate the hex head bolts securing the rear seat cushion in place. Using the appropriate size socket wrench, remove these bolts. In some models, there may be additional bolts or fasteners underneath the seat that need to be removed as well. Once all the fasteners are removed, carefully lift and tilt the seat cushion forward to access the area underneath.

Step 4: Disconnect Electrical Connections

Before removing the rear seatback, check for any electrical connections or wiring harnesses that may be attached to the seat. Carefully disconnect these connections and set them aside, ensuring they are safely out of the way.

Step 5: Remove the Rear Seatback

The rear seatback is typically secured with bolts or fasteners. Using your socket wrench, remove these bolts. If your van has a single rear seat, there may be a lever or release mechanism that allows the seatback to fold down or be removed entirely. Refer to your vehicle's manual for specific instructions if needed.

Step 6: Clean and Inspect the Area

With the rear seat removed, take the opportunity to clean and inspect the area. Look for any signs of damage, wear, or corrosion, especially around the integrated floor access cover. This will be the main area you need to access to reach the fuel pump.

Step 7: Store the Rear Seat Properly

If you plan on reinstalling the rear seat in the future, make sure to store the seat and all its components in a safe and dry place. Label and organise the bolts and fasteners you removed to make reassembly easier.

By following these steps, you should now have successfully removed the rear seating in your Sprinter van, providing access to the integrated floor access cover and the fuel pump. Remember to work carefully and consult a professional mechanic if you are unsure about any part of the process.

Disconnect fuel hoses

Disconnecting the fuel hoses is a crucial step in replacing the fuel pump on a Sprinter van. Here is a detailed guide on how to do this:

Before beginning any work, it is important to take safety precautions. Put on safety goggles to protect your eyes from any debris or fuel spray. Working with the fuel system can be dangerous, so ensure you are in a well-ventilated area to avoid inhaling fumes. It is also recommended to disconnect the negative battery cable to reduce the risk of fire.

Now, locate the fuel pump assembly. For the Sprinter van, the fuel pump is located inside the fuel tank. To access it, you will need to remove the rear seating and the integrated floor access cover. This will expose the fuel pump assembly and the various hoses connected to it.

The next step is to carefully disconnect all the fuel hoses, emissions hoses, and connections from the pump assembly. Take your time with this step to avoid any spills or leaks. Use the appropriate tools to loosen any clamps or fittings holding the hoses in place. You may need to refer to a Sprinter van-specific repair manual for the exact locations and types of connections.

Once all the hoses and connections have been disconnected, you can proceed to remove the pump assembly itself. This typically involves removing a retainer ring or other mounting hardware securing the pump in place. Again, refer to the repair manual for the specific procedure for your Sprinter van model.

After removing the old fuel pump, it is important to clean the area and inspect for any signs of damage or leaks. Ensure that all the hose connections are intact and there is no debris or residue that could contaminate the new fuel pump.

Installing the new fuel pump will involve following the above steps in reverse. Make sure to securely connect all the hoses and fittings, tightening them to the specified torque values. Reinstall the negative battery cable only after all fuel-related work is completed and double-check that all tools and rags are clear of the vehicle.

Finally, perform a test drive to ensure that the new fuel pump is functioning correctly and there are no leaks. Pay attention to any unusual noises, and check for any error codes or warning lights on the dashboard. If any issues persist, consult a certified mechanic for further diagnosis and repair.

Remove the pump assembly retainer ring

To remove the pump assembly retainer ring, you will need to first drain your fuel pump to prevent fuel and vapour leaks. This is an important step to avoid any accidents or fires. Next, disconnect your negative battery cable. You will then need to reach the integrated floor access cover by removing the rear seating and disconnecting the negative battery cable. Now, disconnect all fuel hoses, emissions hoses, and connections from the pump assembly. Once everything is disconnected, you can remove the pump assembly retainer ring and then the fuel pump itself. Be sure to place your replacement fuel pump in the same spot, tightly connecting the seal ring.

Place the new fuel pump

To place the new fuel pump, you will first need to drain your fuel pump to prevent fuel and vapour leaks. Next, disconnect your negative battery cable. Now, reach your integrated floor access cover by removing your rear seating.

Disconnect all fuel hoses, emissions hoses, and connections from the pump assembly. Remove your pump assembly's retainer ring and the fuel pump. Place your replacement fuel pump in the same spot, tightly connecting the seal ring. Re-mount all connections, fuel hoses, emissions hoses, and rear seat floor and seats.

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