I've got an 02 E320 in the shop with only 42000 miles and it runs out and looks brand new. Came in because the automatic door locks would not work. PSE pump was bad so I replaced it and now the locks work every now and then. In addition the pump runs a good bit longer than it should and eventually sets excessive run time on a couple of circuits fault code. I plugged the lines at the vacuum pump that goes to the front that picks up manifold pressure (gasser) and the lines going to the trunk and gas tank door and I still get long run time and the fault codes mentioned. It looks like it goes to working when I reset the PSE. In talking to the owner the evap has been changed which means the dash has been out. In addition it was rear ended and rebuilt to the tune of $8000. My question is where physically does the vacuum lines that go to the front of the car branch off and go to the lines under the dash? I suspect the issue is somewhere between the pump and under the dash. I do not see vacuum on the line under passenger side front tire area when I run the pump. This one has me about pulling my hair out.

tia

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Jim

Could be a multitude of issues causing that leak. The crash could have pinched a line, cracked a line or damaged the trunk lock actuator. Any of the above will cause a leak and the problems you describe. First thing is to pull each individual line off the pump and check to see that each line will hold at the pump end. If not, go to the actuator and see if it holds. If the actuator holds, it's the line.

Thanks - I know it is the line. I've had every door panel off and the plastic inner liner on pass front. I just don't know where it tees off to go to the dash area. I suspect the line going into the dash is what I need to try to plug.

What is strange you can plug the ports to back and intake at the pump and it still throws the extended run time code.

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Jim

Wonder if the pump is also leaking internally?