Retrofitting fuel filter with integrated water separator

AN47.20-S-0002A

Retrofitting fuel filter with integrated water separator

1.2.01



Removing

1

Remove front seat

 Driver's side only.



AR91.10-S-1000A

2

Disconnect ground lead from battery



AR54.10-S-0005A



Notes on battery

AH54.10-P-0001-01A

3

Detach paneling (5) from seat frame (4)

4

Detach fuse box (1) from bracket and place to one side

 Do not damage the retaining clip.

5.1

Remove fuse strip (14) from fuse box (1)

 Applies only for vehicles with the following codes:

L04 Automatic daytime driving light

H15 Heater for front passenger's seat

H16 Heater for driver's seat

HH7 Additional air conditioning system in rear compartment

6

Remove left front door sill molding (2)

7

Detach paneling under left side of instrument panel (6)

 Model 638.294 only

8

Lift floor covering (3) on driver's side

9

Remove instrument cluster



AR54.30-S-6015B

10

Cut through cable straps on plastic cable pouch (7) and guide all electrical connectors down and out of the plastic cable pouch (7)

 The plastic cable pouch (7) remains fastened to the transverse rod behind the instrument panel.

11

Unplug connectors (X60, X61)

 Connector (X60) has 18 pins and connector (X61) has 22 pins.

12

Remove center instrument panel cover



AR68.10-S-3430A

Danger!

Risk of explosion from fuel igniting, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, naked flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

13

Remove fuel filter

 Do not detach the mounting bracket from the fuel filter.



AR47.20-S-5510B

14

Remove air inlet



AR83.25-S-1401A



Installing

15

Retrofit wiring harnesses for fuel filter water separator

AN47.20-S-0001-03A



*220589019900

16

Install connector box cover in engine compartment

17

Install fuse strip (14) in fuse box (1)

18

Install new fuel filter

 Do not connect the fuel lines to the fuel filter yet. Do not install the drain plug yet.



AP47.20-D-0780E

19

Plug connector into water level sensor

 Observe routing of electrical cable.

20

Screw drain plug onto new fuel filter

*BA47.20-N-1001-02F

21

Fasten collar clamp (10) on bracket between timing case cover and oil/water heat exchanger

22

Install drain hose (9) in drain plug and collar clamp (10)

23

Fasten collar clamp (12) on power steering oil line (11) between axle/engine subframe and oil pan (13)

24

Install drain hose (9) in collar clamp (12)

 The drain hose (9) must not touch the oil pan (13).

25

Install air inlet



AR83.25-S-1401A

26

Install water separator indicator lamp (16) in a vacant socket in the center instrument panel cover

27

Plug connector into water separator indicator lamp (16)

28

Install center instrument panel cover



AR68.10-S-3430A

29

Plug in connectors (X60, X61)

30

Install new cable straps on plastic cable pouch (7) and place all electrical connectors inside the plastic cable pouch (7)

 Take care not to unplug the connectors when inserting them into the plastic cable pouch (7).

31

Install instrument cluster



AR54.30-S-6015B

32

Install paneling under left side of dashboard

33

Install left front door sill molding (2)

Install front seat



AR91.10-S-1000A

34

Connect ground lead to battery

 - Code radio.
- Set time.



AR54.10-S-0005A

35

Install fuse (15) in the new or existing fuse strip (14) in socket f34

36

Install paneling (5)

37

Bleed fuel filter

 Start with step 14.



AP47.20-D-0780E

Checking

38

Check function of water separator indicator lamp (16)

 Switch on ignition. The water separator indicator lamp (16) must light up briefly.

Danger!

Risk of accident from the vehicle starting off by itself when the engine is running. Risk of injury with bruises and burns from working on the engine while it is being started or when it is running

Secure vehicle to prevent it from moving off by itself.
Wear closed and close-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

39

Run engine and check fuel filter for leaks

Number

Designation

Engine
611.980/981/983/
987
with code KL5,
engine 612.981 with code KL5

BA47.20-N-1001-02F

Drain plug to filter

Nm

1.5

Part no.

Designation

Quantity

A 000 476 04 36

Collar clamps

2

A 000 545 69 80

Rubber grommet

3

A 001 820 86 01

Switch

1

A 002 545 08 34

7.5 A fuse

1

A 002 545 12 01

Fuse strip F121

1

A 003 545 40 26

Pin

4

A 006 545 09 26

Pin

1

A 008 545 63 26

Pin

2

A 008 545 82 26

Pin

3

A 011 545 81 26

Pin

2

A 013 545 40 26

Connector

1

A 018 545 19 28

Pin

1

A 021 545 60 28

Pin

3

A 115 995 05 65

Collar clamps

1

A 123 995 02 65

Collar clamps

1

A 210 540 21 81

Connector

1

A 611 078 00 71

Drain plug

1

A 611 090 11 52

Fuel filter

1

A 611 997 02 82

Drain hose

1

A 901 540 08 07

Wiring harness

1

no reference no.

Cable terminal M6

1