how to replace fuel release on 1999 mercedes sl500 convertible

3 min read 16-01-2025

how to replace fuel release on 1999 mercedes sl500 convertible

The fuel release cable on your 1999 Mercedes SL500 convertible allows you to open the fuel filler door from inside the car. If this cable breaks or becomes disconnected, you'll need to manually open the fuel door from outside, which can be inconvenient. This guide details how to replace the fuel release cable. Remember, safety first! Always disconnect the negative battery terminal before beginning any work near the fuel system.

Tools and Materials You'll Need

Before you begin, gather the necessary tools and materials:

New Fuel Release Cable: Ensure you purchase the correct replacement cable for your 1999 Mercedes SL500. A local Mercedes-Benz dealership or a reputable online parts supplier is recommended.
10mm Socket: For removing the screws holding various panels.
Phillips Head Screwdriver: Possibly needed depending on your specific model.
Panel Removal Tools: Plastic pry tools are recommended to avoid scratching the interior.
Wire Cutters/Strippers: For cutting and stripping the cable ends, if necessary.
Gloves: To keep your hands clean.
Shop Rags: For cleaning.
Patience: This can be a fiddly job.

Step-by-Step Guide to Replacing the Fuel Release Cable

This process involves working within the car's interior and may require some patience.

Step 1: Accessing the Fuel Release Mechanism

Open the Trunk: Begin by accessing your trunk.
Remove the Trunk Liner: You'll need to remove sections of the trunk liner to access the fuel release mechanism. Consult your owner's manual or search online for specific instructions on removing your SL500's trunk liner. This often involves removing screws and carefully prying away plastic clips. Take your time to avoid damage.
Locate the Fuel Release Cable: Once the liner is partially removed, locate the fuel release cable mechanism. It's typically located near the area where the fuel filler neck enters the trunk.

Step 2: Disconnecting the Old Cable

Disconnect the Cable: Carefully disconnect the old fuel release cable from its linkage at the fuel filler door mechanism. This may involve unclipping or unscrewing a connector.
Trace the Cable Route: Trace the cable's path from the fuel filler door mechanism back through the car's interior. Pay close attention to how it's routed and secured. Take pictures if it helps!
Remove the Old Cable: Once the cable is disconnected, gently pull it out from the trunk area. You may need to release some clips or fasteners along the way.

Step 3: Installing the New Cable

Feed the New Cable: Carefully feed the new fuel release cable along the same path as the old cable. Take your time; it needs to go in the same route and clip back in correctly.
Connect the New Cable: Connect the new cable to the fuel filler door mechanism at the end. Ensure it's securely attached.
Secure the Cable: Make sure the cable is properly secured along its route and that no parts are loose. This often involves using existing clips or fasteners.

Step 4: Reassembling the Trunk

Reinstall the Trunk Liner: Once the new cable is installed and secured, carefully reinstall the trunk liner panels, ensuring everything is aligned correctly.
Test the Fuel Release: Close the trunk and test the new fuel release cable by pulling the interior release lever. The fuel filler door should open smoothly.

Troubleshooting

Cable Doesn't Reach: If the new cable doesn't quite reach, double check the route and ensure it's following the same path as the old one.
Cable Doesn't Function: If the fuel filler door doesn't open, check the connections at both ends of the cable. Make sure the lever is working.
Damaged Parts: If you find additional damage or broken parts during the process, replace them to ensure a long-lasting fix. A damaged clip might be the root of the problem!

This guide provides general instructions. Specific details might vary slightly depending on the exact year and model of your Mercedes SL500. Always consult your owner's manual or a Mercedes-Benz repair manual for detailed diagrams and specific instructions. If you're uncomfortable performing this repair yourself, consult a qualified mechanic. Remember to always prioritize safety when working on your vehicle.