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2003 E320 Bad Fuel Sending Unit?

1.3K views 2 replies 2 participants last post by  HoloDoc  
#1 ·
First a little background.

Purchased this vehicle back in March 2021, total of ~46000 miles, has 47600 now. It hadn't really been used all that much over the last 18 years, so was in need to some TLC.

Maintenance performed by me:
  • Spark plugs replaced
  • Oil changed
  • Air filter replaced
  • Valve cover gaskets / hoses replaced
  • Transmission fluid drain fill + filter
  • Fuel pump and sender unit replaced (7-1-21)
  • Brake pads/rotors replaced
  • Engine/Transmission mounts replaced
  • Windshield washer line replaced

Okay, here is where it starts getting interesting. Car starts to have rough idle and eventually leads to a P0305 (misfire on cylinder 5). I replace the Crankshaft position sensor (I had a spare on hand), cleaned the throttle body, and inspected the spark plugs/wires for cylinder 5 (did replace 1 wire as it was really loose). While cleaning the throttle body, I replaced the small vacuum line that was dry rotted.

No change, same problem - rough idle and a P0305. A little more reading and research, I replace the Camshaft position sensor and all is better - she purrs like a kitten (mostly).

Now, the new stuff:
  • Driving along, now have a P0106 and pending P0451. Resetting the CEL, and driving home, had pending CEL for P0106 and Lean Bank 1 and Lean Bank 2 (which I figured were due to the P0106).
  • After replacing the MAP (hose looked okay). I took it for a test drive, and when I got home had a pending P0451.

Everything seems to point to me needing to replace the fuel sending unit (again). Does that make sense, or is there something I might be missing? Obviously it will take some time to get a replacement unit in, so I suspect I'll be living with the CEL for awhile.
 
#2 · (Edited)
What brand fuel sending unit did you install? Didn’t it come with a new pressure sender that requires a pigtail adapter? Make sure the contacts are clean and securely engaged.

The pressure sender can be removed from the replacement style sending unit assembly. You have to bend away a locking tab then lift up the sender. Be very careful to not tear the accordion seal when fitting the sender. Mind fuel tank level as the sender is lower than the top of the tank! Half a tank might not be low enough and the tank can have residual pressure!

Check the hard plastic lines in the engine bay. You might have disturbed an evaporation system line when you removed the driver side valve cover.

Also go back and check the vacuum hoses at the front of the engine or just replace them on principle. I wouldn’t mess with the one that tucks under the intake manifold because you might get it off but you won’t get it back on. Check the couple of hoses at the EGR valve.

Sixto
05 E320 wagon 178K miles
 
#3 ·
Fuel pump and sending unit are VDO brand (ordered from FCP Euro) with the pigtail adapter. So probably not the culprit. Used new seals as well. Fuel system is a PITA and need it close to empty to be able to do anything meaningful.

I did go back and recheck hoses. Apparently in my work to clean the throttle body, i either neglected to reconnect the Evap line going back into the rebreather connection at the top of the throttle body or just loosely attach it and it wiggled free.

Reconnecting that seems to have settled the engine down again. Still need the system to work through all of its Emissions checks, but hopefully that addresses the issue.

Bottom line - check those hoses.

Will continue to monitor for the fuel system, but engine should be taken care of since there was ‘some’ unmetered air getting in the system and I’ve plugged that leak.