Replacing Fuel Pump In 2006 Merc: Step-By-Step Guide

Replacing the fuel pump on a 2006 Merc 4-stroke can be done without removing the fuel tank. The fuel pump is located in the right side of the fuel tank. With the seat removed, you will see the access panel to the fuel pump on the right-hand side. There are several steps to replacing the fuel pump, including removing the rear seat, draining the fuel tank, and disconnecting the negative battery cable. It is important to work in a well-ventilated area and take extreme caution when working around fuel.

Remove rear seats and seat covers

To access the fuel pump of your 2006 Merc 4-stroke, you will need to remove the rear seat and seat covers. This will allow you to access the fuel tank and the fuel pump assembly. Here is a step-by-step guide on how to do it:

Step 1: Remove the Rear Seat Cushion

Start by pulling the driver-side rear seat bottom cushion forward. There may be bolts or clips holding the seat cushion in place, so you might need to unscrew or unclip them before lifting the cushion out. Be sure to check if there are any bolts or clips holding the seat cushion in place and remove them carefully.

Step 2: Locate the Access Panel

Under the rear seat cushion, you will find a cutout in the carpet. This is the access panel for the fuel tank. It is important to be careful when moving the carpet and any other components in the area, as they can be delicate.

Step 3: Remove the Seat Covers

To remove the seat covers, you will need to lift them from both sides at the front edge. There may be clips or hooks holding the covers in place, so be sure to carefully unclip or detach them before removing the covers. Some models may have a bar across the rear, which is for side impact or to strengthen the rear on AWD models.

By following these steps, you will be able to access the fuel tank and fuel pump assembly of your 2006 Merc 4-stroke. Remember to put back the rear seat and seat covers carefully after completing the necessary repairs or maintenance.

Disconnect the SRS cables

Disconnecting the SRS cables is a crucial step in disabling the airbag system and ensuring your safety when performing maintenance on your 2006 Merc. Here's a detailed guide on how to do it:

Step 1: Turn Off the Ignition

Start by turning off the ignition of your 2006 Merc. It is important to never attempt to disconnect the SRS cables or work on any electrical systems with the car powered on.

Step 2: Locate the Battery

Pop the hood of your car and locate the battery. It is typically a large, block-like component with two large cables attached near the engine bay's surface. Consult your owner's manual if you're having trouble locating it.

Step 3: Identify the Negative Terminal

Once you've found the battery, identify the negative terminal. It is usually marked with a "-" symbol and may have a black plastic cap. The positive terminal, in contrast, will be marked with a "+" sign and a red plastic cap.

Step 4: Disconnect the Negative Cable

Remove any plastic caps from the battery terminals. Using a suitable wrench, loosen the nut on the negative terminal by turning it counterclockwise. Then, remove the negative connector cable and ensure it is pushed aside and clear of the battery.

Step 5: Disconnect the Positive Cable

Repeat the same process for the positive terminal. Loosen the nut with the wrench and remove the positive connector cable. Ensure that it is also pushed aside and doesn't come into contact with the battery.

Step 6: Wait Before Proceeding

It is important to allow time for the system to discharge completely. Refer to your 2006 Merc's service manual for the specific amount of time recommended. Do not rush this step, as it is crucial for your safety.

Step 7: Disconnecting the SRS Connector

Before removing any SRS parts, always disconnect the SRS connector. This is a critical step to prevent accidental airbag deployment. Refer to your vehicle's service manual for the exact procedure, as the process may vary slightly depending on your specific model.

Step 8: Handling Precautions

When handling SRS parts, always exercise caution. Do not disassemble any SRS components, and avoid dropping or mishandling them. Always use new, high-quality replacement parts that meet the same standards as the original equipment.

By following these steps, you can safely disconnect the SRS cables on your 2006 Merc. Remember to refer to your vehicle's service manual for additional model-specific information and always prioritize your safety when working on any vehicle maintenance or repair tasks.

Remove the rear seat bottom covers

To remove the rear seat bottom covers of a 2006 Merc, start by pulling the driver's side rear seat bottom cushion forward. You will see a cutout in the carpet, and under there is the access panel of the fuel tank.

Now, to remove the rear seat bottom covers, follow these steps:

Release the bib panel:

The bottom seat cushion covers usually attach to the seat with straps, buckles, and S-hooks. Disconnect the bib panel by reaching under the seat and unhooking the straps. The bib panel is connected to the seat springs with either clips or an elastic strap. Once the straps are disconnected, lift the bib to access the gap between the seat back and the bottom cushion.

Thread the straps:

Fit the seat cover onto the bottom cushion and thread the rear straps through the gap. Push the bottom cushion straps through the gap and pull them completely through until the seat cover is taut.

Buckle the seat cushion straps:

Route the bottom cushion straps toward the front of the seat, ensuring they do not interfere with the seat adjuster mechanism. Thread the straps into the buckles and tighten them to remove wrinkles from the seat cover.

Tighten and connect the bungee cords:

Pull on the bungee cords to tighten the skirt on the bottom seat cover, then connect the ends using the supplied S-hook. Tuck any excess fabric behind the plastic trim panels.

Remove the cushion:

If you need to remove the rear seat bottom cushion entirely, run your hand along the front edge to locate the latch points. Try jerking straight up at these points. If the cushion is still attached, push it straight back as you lift it up to release it from the hook latches. Then, set the cushion on a bench outside of the car.

Disconnect the fuel lines

Disconnecting the fuel lines is one of the most challenging tasks when changing the fuel pump on a 2006 Merc 4-stroke. There are various types of fuel line styles, so it's important to understand the specific style you're working with. Here's a step-by-step guide to help you through the process:

Push-Type Connector:

Locate the push point on your connector. Some have push points on both sides, requiring you to push from both directions to release it. Others have a push point on only one side; simply push it down and pull it off. To reinstall, push the connector until you hear a click.

Push-and-Lock Style Connector:

This type of connector requires you to push it onto the fitting and then push the locking tab through. To remove it, locate the safety line beneath the fitting. Release the safety latch and push the connector back through.

Pinch-Type Connector:

Look for retainers on each side of the connector. Pinch these together to disconnect. For reinstallation, you have two options. You can either leave the retainer on the male end and slide the female fitting over it, or remove the retainer and slide the fitting onto the male fitting until you hear a click.

Spring-Style Retainer Fitting:

To install this type, slide it on until you hear a click. For removal, locate the black ring, which serves as your release tool. Pull it back toward the fitting and then remove the fitting.

Hose and Clamp Style Fitting:

This style is typically used for emissions lines. Use pliers to pinch the clamp together, slide it back, and then pull the line off.

Additional Tips:

• If the fuel lines break while removing them from the fuel pump, leaving part of the line in the fitting, use a release tool. Insert a screw or bolt that fits into the line and pull out the fitting.
• When dealing with spring-type connectors, a short piece of zip-tie can be curled and stuffed into the connector as an alternative method.
• If you encounter a horseshoe-type fitting, use a screwdriver to carefully pull the horseshoe up and out.

Remove the old fuel pump

To remove the old fuel pump on your 2006 Merc 4-stroke, you'll need to first locate the fuel pump access panel. Here are the steps to follow:

• Pull the driver's side rear seat bottom cushion forward.
• Locate the cutout in the carpet. Under this cutout, you'll find the access panel for the fuel tank, which houses the fuel pump.
• Remove the access panel. You may need to refer to YouTube videos or specific repair manuals for your Merc model to understand how to safely remove this panel without damaging any surrounding components.
• Once the access panel is removed, you should be able to see the fuel pump assembly.
• To remove the old fuel pump, you'll need to disconnect it from the fuel lines and any electrical connections. Make sure to do this carefully, as the fuel lines may be fragile and prone to leaking if not handled properly.
• After the fuel pump is disconnected, carefully lift it out of the fuel tank. You may need to refer to a repair manual or seek advice from a Merc mechanic if you're unsure about the exact procedure for your specific model.
• Place the old fuel pump aside, making sure to dispose of it properly or recycle any usable parts.

Remember to exercise caution when working with fuel systems, as they can be dangerous if mishandled. If you're unsure about any steps, it's always best to consult a qualified mechanic or seek advice from a Merc-specific forum or community.

Frequently asked questions