Replace fuel filter

AP47.20-P-0780EWD

Replace fuel filter

08.07.2016

Engine

651 in model 166, 172, 205, 207, 212, 218, 222, 253

Shown on engine 651 in model 204.001

1

Fuel hoses

3

Clips

6

Condensation sensor for fuel filter with heating element

2

Fuel filter

A

CLIC clamps

7

Fuel preheating system heating element

Shown on engine 651 in model 204.001

1

Fuel hoses

2

Fuel filter

3

Clip

4

Drain hose

5

High pressure pipe

6

Condensation sensor for fuel filter with heating element

A

CLIC clamps

B

Cable tie

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Danger !

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

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Preparatory activity

1

Switch electronic ignition lock control unit to position "0"

2

Open engine hood and raise to vertical position

Engine 651 in model 166, 172, 205, 207, 212, 218, 222, 253



Model 166 with engine 651

AR88.40-P-1000GQ



Model 207, 212 with engine 651

AR88.40-P-1000EW

 Engine 651 in model 207, 212
with code U60 (Active Bonnet (Pedestrian protection))
Moving the engine hood to the vertical position:
Detach left and right clamping levers at the upper left and right hinges.

3

Open and close tank cap

 in order to reduce the pressure in the fuel tank.



Remove

4

Remove engine cover

Vehicle with engine cover.

5.1

Release and disconnect electrical connection from condensation sensor for fuel filter with heating element (6)

Vehicle with condensation sensor for fuel filter with heating element (6).

5.2

Release and disconnect electrical connection from heating element for fuel preheating (7)

Vehicle with heating element for fuel preheating (7).

6

Detach fuel hoses (1) at fuel filter (2)


Loosen the fuel hoses (1) by turning by hand (do not use any sharp-edged pliers), or push them off the fitting using a blunt object (plastic wedge) or a blunt or broad-edged tool.
Otherwise, the fuel-resistant liner may be injured and the fuel system damaged.

 Collect any leaking fuel.

 Pliers for click clamps

*171589003700



Check

7

Check fuel hoses (1) for damage

If there is a problem



Rectify problem subject to separate repair order.



Remove

8

Open cable tie (B) and unfasten drain hose (4)

Fuel filter (2) with drain hose (4).


Do not detach drain hose (4) from fuel preheater heating element (7) or fuel filter condensation sensor with heating element (6).
Damage can otherwise occur.

9

Pry open clamps (3)

10

Remove fuel filter (2) upwards

Modify

11.1

Convert condensation sensor for fuel filter with heating element (6) to new fuel filter (2)

Only for fuel filters (2), in which the condensation sensor for the fuel filter with heating element (6) is not included.

 Screw/bolt, fuel filter water level sensor to fuel filter

*BA47.50-P-1001-01A

11.2

Convert heating element for fuel preheating (7) to new fuel filter (2)

Only for fuel filters (2), in which the heating element for the fuel preheating (7) is not included.

 Screw/bolt, fuel filter water level sensor to fuel filter

*BA47.50-P-1001-01A



Install

12

Install new fuel filter (2) from above


Press down fuel filter (2) as far as the end stop.
Damage can otherwise occur.

13

Fasten fuel filter (2) in place using clamps (3)

14

Position drain hose (4) and fix in place with new cable tie (B)

Fuel filter (2) with drain hose (4).


Do not kink, crush or twist drain hose (4).
The drain hose (4) must be routed exactly as shown and fixed using a cable tie (B) to the high-pressure line (5).
Damage can otherwise occur.

15

Attach fuel hoses (1) using new CLIC clamps (A) to fuel filter (2)


Replace CLIC clamps (A). Do not use screw clamps or spring bracket clamps.
Otherwise this may lead to leakage and consequential damage.

 Collect any leaking fuel.

 Pliers for click clamps

*171589003700

16.1

Connect and lock electrical connection to heating element for fuel preheating (7)

Vehicle with heating element for fuel preheating (7).

16.2

Connect and lock electrical connection to condensation sensor for fuel filter with heating element (6)

Vehicle with condensation sensor for fuel filter with heating element (6).



Check

 Danger !

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

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

AS00.00-Z-0005-01A

17

Start engine and check fuel system for leaks


Before the engine is started, the electronic ignition lock control unit must be switched to position "2" (circuit 15) for 5 s in order to fill the new fuel filter (2) with fuel.
Otherwise, the fuel injection system may be damaged.

 The components of the fuel system that were worked on when changing the fuel filter are to be checked for leaktightness.

If a leak is detected.



Switch electronic ignition lock control unit immediately to position "0", clean up any leaked fuel, determine and rectify reason. Then perform operation step 17 again.

18

Switch off engine



Install

19

Reinstall engine cover

Vehicle with engine cover.

Finishing activity

20

Close engine hood

Engine 651 in model 166, 172, 205, 207, 212, 218, 222, 253



Model 166 with engine 651

AR88.40-P-1000GQ



Model 207, 212 with engine 651

AR88.40-P-1000EW

 Engine 651 in model 207, 212
with code U60 (Active Bonnet (Pedestrian protection))
Close engine hood:
Mount left and right clamping levers at the upper left and right hinges.

 Sensors, transmitters

Number

Designation

Engine 651

BA47.50-P-1001-01A

Screw/bolt, fuel filter water level sensor to fuel filter

Nm

2