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My hole is 5 inches and I was looking at the 6 inch OD cover they have but it would only give me a half inch overlap for the gasket. I’m not sure that would be enough and it looks like the gasket works to seal the bolts? My bolts would be right on the edge
 

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You may be able to cut slots in the body at the cover under the seat to allow the larger 8" to be installed and removed as necessary. As long as the slots are covered by the inspection cover under the seat you should be sealed against noise and the weather. The tank cover seals the tank. The inspection cover seals weather and noise. Just my thoughts on this. Mark
 

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Any Progress on the pump swap?
Yes I’ve made some progress:
Font Jewellery Newspaper Metal Fashion accessory


I took the new pump that I bought apart and swapped it into the old housing, what a pain. The diameter of the new pump is slightly larger than the old pump so I had to use a Dremel and modify the plastic holders so if they would fit the new pump, prob the same way you did. It was also slightly longer so I had to trim the rubber rings down as well. Now I need to alter the wires and reinstall in tank.

I almost just stuck the new pump housing in the hole and called it good but with pump not sitting on tank bottom that way, it would have run dry while gauge said there was some left.
 

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I remember trying to make sure the new pump was located firmly inside the module so I would not get any buzzing noises when it ran. Had to splice the wire connectors from the new pump to the wire connector from the old pump. My big concern was the filter on the pump bottom. The new filter from my Carter pump would not fit in the factory module. I ended up using the factory pumps filter and I did not like doing that since it was used. They really can’t effectively be cleaned because it is a micro filter And I did not find a new similar filter available.
 

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Just to confirm for future needs of members. The 2007 Mercedes S550 Fuel Pump is a direct drop in part for the E350 PZEV fuel pump. They are identical but for some reason the S550 pump can't be shipped into California? To use the S550 pump you would still need to remove the fuel tank from the car and safely modify the tank to remove the old pump, install the new pump and seal it back up by either welding it shut or installing a trap door. I wish I had been aware of this pump availability when I first had mine apart it would simplify the job. BTW: This particular pump is available either $350 for a quality pump or other low cost guys sell it for as little as $50. If you just had a removable access door you could install one without removing the rear suspension, Exhaust and entire fuel tank from the car.
 

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1999 S500; W140.051; 2003 E320; W211.065; 1973 220; W115.010
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Fuel Pump - Mercedes-Benz (211-470-21-94)

2010 Mercedes-Benz SLK 55 AMG® Base 5.5L V8 - Gas
2009 Mercedes-Benz SLK 55 AMG® Base 5.5L V8 - Gas
2008 Mercedes-Benz SLK 55 AMG® Base 5.5L V8 - Gas
2007 Mercedes-Benz SLK 55 AMG® Base 5.5L V8 - Gas
2006 Mercedes-Benz SLK 55 AMG® Base 5.5L V8 - Gas
2005 Mercedes-Benz SLK 55 AMG® Base 5.5L V8 - Gas

I don't see anything saying it can't be shipped to CA.
 

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Good to know. Gives an option for those with mechanical ability not wanting to buy the $2400 PZEV replacement tank.

The pump you listed Mercedes-Benz (211-470-21-94) is not the pump that fits. I will try and find the match. It is the pump for a 2007 S550 that matches, EDIT: some sites show the proper pump fits the 2010 S550 so don't limit search to the 2007 model year, not sure what other models it also fits but the S550 pump is inside the 2007 E350 PZEV sealed tanks. Mercedes-Benz (221-470-84-94) looks like the correct part.

Edit for correction 4-30-22, I ended up ordering a Delphi Fuel Pump CFE0727, fits a 2008 Mercedes S550 plus many other models, the picture showed a good match and it is a $289 part locally. My pump installed a few months back had started to growl a little, it also was not holding pressure when engine was shut off which bothered me. The car started and drove perfectly but I lost trust so I just popped my new cover and installed a new pump.
The Delphi FE0727 pump was identical but the module that holds the pump was just a touch off. The hold down locks could not be used, the pump needed to rotate a little. I could have modified it to work but I realized my old pump module body was perfect, it just needed the new pump and filter so I used the new parts from the Delphi module. In about 5 minutes I swapped the pump from the new body module ( the plastic container that holds the pump) to my old body module and the pump lined up perfect on install. The Pump power wire and ground wire hook up a little differently, my old pump was soldered on the new pump had two male spade connectors on the pump, so I crimped female wire spades on my wires and hooked up the new pump. Now it holds pressure on shut off, only lost 5 lbs pressure in 30 minutes after shut off, that is good, with the Carter pump it never held pressure after shut off. The car seems to run even better. I take the blame on the first pump failure, figuring out the PZEV conversion I am sure I got some debrie into that pump which killed it, pumps only run on clean fuel, any dirt damages the fuel lubricated motors. I washed out the tank before the install but it was apart and together a few times as I worked things out. The Delphi pump was a much better fit than the Carter pump I used first and it has really good reviews at several places.

Edit, I should have noted, the new cover I installed on the passenger side to allow access to the new fuel pump is an 8” cover, the access hole below the rear seat is only 7”. To change the pump with this large cover in place I had to remove the nut that bolts the tank to the inside passenger compartment. A 13mm nut is dead center under the pass seat on the driveshaft tunnel. Remove this, now go under the car and remove all 4 bolts on the gas tank straps. The tank will sag about 2” down but your driveline and exhaust are there so it can’t fall out. This extra 2” allowed me to slip the new pump cover over the top of the tank where I left it while I installed the new pump. On install I just reversed the procedure. Once the cover was on again and tight I went under the car. Pressed the tank up and started the strap bolts. Then I went inside and installed the 13mm tank bolt which is under the rear seat. Now I went under again and tightened the 4 tank strap bolts. I forgot to mention, to access the strap bolts you do have to remove two heat shields, they have 6 bolts each side that are plastic 10mm zip nuts. Sounds like work but the whole lower the tank process did not take 15 minutes. Much easier than dropping the entire rear suspension and the exhaust to access the fuel tank. Just a follow up FYI. The car really does run perfectly, I am very happy with the results and I am pretty picky. Fuel Pressure is a very steady 58 PSI and holds after shut off And it is quiet.
 

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As you have told us, it's not an easy job but even the PZEV fuel tank replacement isn't really an easy DIY either.

For those motivated and capable DIY'rs ready to take it to the next level, you have provided a validated roadmap. A major accomplishment IMO.

I think this whole PZEV option is an example of politics gone wrong leaving the likely unaware customer with the brutal cost consequences.

Such a messy world.
 

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If Mercedes had just included the removable cover on the PZEV tank like they do on all other tanks this would be a 1 hour easy job now that we know what pump is in the PZEV tank.
For peace of mind I would purchase the Mercedes replacement pump rather than modify the factory module with a new pump like I did. The cost increase is small and it saves time. EDIT, see notes above for the corrections to this process.
 

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If Mercedes had just included the removable cover on the PZEV tank like they do on all other tanks this would be a 1 hour easy job now that we know what pump is in the PZEV tank.
For peace of mind I would purchase the Mercedes replacement pump rather than modify the factory module with a new pump like I did. The cost increase is small and it saves time. EDIT, see notes above for the corrections to this process.
Hey West,

How's the repair holding up?
 

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2000 S430, 2000 S500, 2003 S600 TT, 2005 E320 CDI, 2006 S500 4Matic, and 2006 S350
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Probably easier to drive a 1977 Chevrolet Nova.
Each car, and car model, has its own quirks, even Hondas. This happens to be a quirk of the W211. It's thanks to other forum members like the above that we have ways to mitigate pretty much all of those quirks.

That said, nothing wrong with 1977 Chevrolet Novas, if that's what one prefers.
 

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The Fuel Pump Repair is perfect now. As noted I did put a new Fuel Pump In, using the new trap door. Same car got new Timing Chains, Balance Shaft, Tensioners and guides right after the fuel pump repair. Runs like a top, has not set any codes since the repair. I bought this car broken to fix it and I did this, job completed I sold the car a couple weeks ago. I was much happier with the Mercedes pump installed, it was quieter and easier to install. The modified Carter pump I used was a little noisier. As far as Nova’s, my first car was a 1971 Nova Super Sport, I loved that car, the 1977 body I was never fond of and by 1977 the engines had no power at all.
 

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My hole is 5 inches and I was looking at the 6 inch OD cover they have but it would only give me a half inch overlap for the gasket. I’m not sure that would be enough and it looks like the gasket works to seal the bolts? My bolts would be right on the edge
I just received all of the parts to do this job. How did you end up re sealing your gas tank? Did you install a fuel access door ? I am thinking of doing a JB Weld as my car has 181k miles and if I service the fuel filter I can get the fuel pump to do another 200k.

thank you
AG
 

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RTV = room temperature vulcanizing sealant. I don’t think there’s RTV that’s suitable for fuel tank service.

Sixto
05 E320 wagon 195K miles
I'm just reporting what other posters have mentioned in other threads. Not sure what they used but maybe it worked for a little while before it failed. But there is RTV out there that's supposed to work with gasoline and maybe the guy used this, but who knows?

 
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