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Broke fuel line 02ML500 to fuel tank

12K views 96 replies 6 participants last post by  Witek_M  
#1 ·
Hi I have a problem on my 02 ML 500 where it won't start and I'm getting 0 fuel pressure, I checked all fuses and they were fine so I decided to change the fuel pump and filter, I have the new pump installed and I am trying to install the new lines, I purchased the three lines required (2 from pump to filter) and one loop line to the fuel feed but I don't have that setup as this is an 02 ML, while disconnecting the old fuel filter I broke the third line and kept pulling at it more because I thought it would eventually come off and I would find a spot to connect the loop line. Now I am almost at the point where there seems to be a metal valve (like a tire valve) of some sort where the fuel feed (loop) line would be coming from on a 98 ml and I read some posts saying that this line runs all the way to the engine and is a costly fix. Would I be able to get some fuel line and clamp it on both sides to the filter and where the loop line would attach? The connector would not budge at all and I don't think my fuel filter has ever been changed as many of these bolts broke in the process of trying to take them off. Even if I could've taken it off at the fuel filter and reattached it to the new one it just seemed that it was so worn out that it needed to be replaced. Any help is greatly appreciated. I hope there is a way of being able to fix this without replacing that entire line.
 
#6 · (Edited)
The black hose delivers fuel under pressure to your engine. You can decide how important it is, if you want to fix it properly or attempt a bodge-up job.

You don't have the tools required to DIY the fuel line. Prepare yourself for the idea that you need to have it towed to a workshop.

Whatever happened to: "Hey guys, I'm planning to change my fuel filter. Should I buy the $10 pliers, or just use force?"
https://m.ebay.com/itm/220mm-Car-Pe...rol-Fuel-Line-Plier-Clip-Pipe-Hose-Release-Disconnect-Rubber-Tool-/311970129502
 
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#11 ·
So this post is almost two years old and I've had the vehicle stored, I am looking to get it fixed now and would appreciate any help going forward, I also thank you all who have contributed to this post. First my ML stalled and would not start up again, I replaced the fuel pump, and fuel filter but during the process I broke the "service only line" that runs to the engine, I stupidly did not purchase the $10 tool needed for this job, what parts exactly would I need to have this fixed? I know some have mentioned patching this line but not sure if that would be a good approach? The vehicle is an 02 ML500 and my next reply will be of the link to the video showing the line I am talking about and where it broke.

Thank You all for your help, I would really like to have my ML back on the road this summer.
 
#27 · (Edited)
Would I even need the service loop line?
No. You don’t need the loop line.

As the note under the diagram explains, your 2002 ML is fitted with the larger filter, so it doesn’t require the extra line.

The original filter was shorter and fit directly onto the black fuel line. After they discontinued it, the simplest way to fit the longer filter was to run the loop.

Your ML has a shorter fuel line that connects directly to the fuel filter. When you correctly order part #95 in the diagram, they will send you the shorter line that matches your long filter.

You wasted your money buying the “service only” loop line. But that was 2 years ago.

(I am replying to the question for 43sqd in case he has given up on you.)
 
#33 ·
Thanks to the help of everyone on the forum I was able to get the required parts in. It appears that everything matches up and requires no additional connectors to work as I was told. I should be having a friend do the work sometime this week and I was wondering if anyone had any info that would be helpful to him maybe a worksheet or any tips? Rocketman4321 mentioned on another post
“I have done the job, and it's nowhere near as bad as it sounds--really quite straightforward. (I chewed up the line on the first filter change--with the official tool--and it gave out on the second change.) I lifted the near side and loosened the far side and that worked well. It's really just 8 or 10 (big) bolts--there's no reason to minimize; just loosen them. Then jack the body with a big piece of wood to spread the load. You just need enough clearance to hop the old line out over the body mounts.

Parts.com has the line. Mine arrived with a connector rather different from the original, and it was missing the "keeper'. Fortunately it's a Ford Dorman connector and the local auto parts had the missing piece. (5/16" if I remember correctly). You could also try installing an aftermarket connector in the old line, but I think that takes a $30 tool, so you're almost at the cost of a new line.

And the job gives you time to contemplate why Mercedes has such an utterly idiotic filter location.” So if that’s all it is I will post back and give you guys some updates.

Thank You!
 
#34 ·
In this PDF posted by 43sqd in another post at the end it mentions a pressure hose and a clamp. Pressure Hose 119 589 04 63 00 and clamp 000 589 54 37 00. Is that the service valve where you release fuel pressure or is the hose and clamp another special set of tools I would need to replace the line. Also if I need any special MB tools please let me know! My friend has many clamps but not sure if it’s a special kind.
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Thank You
 

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#38 ·
Fuel line is replaced, new fuel filter and pump, new starter, CPS, and battery. Fuel pump isn’t making any noise. What should I do as my next diagnostic approach? Fuel pump relay K3 and Fuse 13 are ok. Also no fuel at fuel rail and red AAM light appears to be blinking which is a good sign.

Thanks for your help.
 
#39 · (Edited)
Check to see if you voltage at the fuse (hot side) then at the pump to eliminate bad wire or ground.

I12v at the fuse box and not at pump
Then wire harness is bad or bad ground or the out put on the fuse is bad.

If no 12 v on hot side fuse something is wrong there


12 v fuse and pump bad pump.

The fuse should be driver side kick panel the blocks are modular and span in and out could also be it is not set correctly or the sunroof drain leaked corroding it. Pull it out look it over note how it sets before removing.
 
#42 ·
Test light would work but a multi meter s better. Pull fuse stick probe in the hot side of fuse do not be too forceful you do not want to bend the spring that clamps on the fuse lead then you need tho find a goof ground and ground black lead.

Can’t remember which fuse it is but it is left side f13 sounds right