Fuel Gauge Sender: Service and Repair

Removing And Installing Fuel Level Sensor







NOTE:
- The two sensors have different shapes and may not be switched.
- The float installed in the left direction of travel is flat, while the float installed in the right direction of travel is spherical.
- The removal of both sensors is explained in parallel in this description. If only one sensor has to be removed, the other side of the tank can remain untouched.

WARNING:
Danger of fire.
- Keep clear of ignition sources.
- Do not smoke.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge.
- Danger of fire due to hot exhaust system. Always allow the exhaust system to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO(2) or dry powder fire extinguishers.

CAUTION:
- Please observe general warning notes and working regulations.
- For safety reasons, the tank should only be removed and installed when empty.

Removing fuel level sensor

NOTE: All windows should be opened for better ventilation in the passenger compartment.

1. Fold rear seat forwards.
2. Fold up the retaining brackets of the relevant belt anchors. To do so, undo the three fastening screws and fold up the brackets with the belt anchors. Do not use the fastening screws again.







3. Undo both caps. To do so, cut out the carpeted floor along the perforated lines using a carpet knife and fold it over. Then unscrew the four fastening nuts and remove the lids.







4. Empty the fuel tank.
5. Carefully pull off all electric plugs and connection lines on the relevant connection unit.







CAUTION:
- Fuel vapours will penetrate the passenger compartment when you open the locking unit. Ventilate the vehicle well.
- Do not spill fuel into the passenger compartment.
- Ensure good ventilation when working on open fuel tank.
- Wear suitable protective equipment (breathing mask and protective gloves) when working on the tank.
- All seals must always be replaced.

NOTE:
- Replace the cap seals.
- If the tank must be opened for emptying, disconnect all connections.

6. Open the required cap with the key T10202 and lift up the connection unit.
7. Disconnect the electric plugs -1 and 2-. Then pull off the fuel lines -3 and 4- and remove the connection unit.







8. Reach carefully past the fuel pump and feel for the sensor. This is located in front of the pump, pointing diagonally outwards.
9. Press the retaining spring on the sensor by hand while at the same time pulling the sensor up.







Installing fuel level sensor
1. Install a new fuel sensor. Press the sensor into its mounting point. The retaining spring must engage audibly.

View shows the left sensor







View shows the right sensor







2. Fit new seal in the opening of the tank.







3. Connect connection unit. Connect the electric plugs for the fuel level sensor and fuel pump. Then push on the fuel lines. The connectors must engage audibly.







4. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.
5. Close the tank. To do so, fit the sheetmetal ring and tighten to a tightening torque of 140 Nm (104 ftlb.) using key T10202.







6. Fit all connections (fuel lines, ventilation tubes and electric plugs).







7. Fit lids. Tighten the four fastening nuts to 10 Nm (7.5 ftlb.). Refit carpeted floor and fix with double-sided adhesive tape.







8. Tighten the belt anchor fastening plates. Use three new fastening screws for this and tighten to 20 Nm (15 ftlb.).







9. Fold rear seat down again.
10. Refuel the vehicle.

Tightening torques