Removal and Replacement

Removing And Installing Fuel Level Sensor

Tools

Tools:

Preliminary work

Preliminary work - Carrera 2
1. Place protective covers on the vehicle.
2. Disconnect and remove battery.

3. Remove carrier plate for battery. Unscrew four M8 hexagon collar nuts -1- and remove lid. Check seal for damage and replace it if necessary.

Preliminary work - Carrera 4
1. Place protective covers on the vehicle.
2. Disconnect the battery.
3. Remove luggage compartment cover.

4. Remove cover for tank flange. Unscrew four M6 cap nuts -2-, remove the four washers and lift off the lid. Check seal for signs of damage.

Removing fuel level sensor

Removing sensor - Carrera 2

DANGER:
Risk of fire from escaping fuel.
- Danger of fatal injury and damage to property.
- Observe basic safety instructions when working on the fuel system.
- Secure working area.

Tools:

Tool for Row variant.

Tool for all USA variants of Carrera 4 and Carrera 2.

NOTE: Watch out for emerging fuel when disconnecting fuel lines. Place a clean cloth on the connection point, then loosen the connection.

1. Disconnect plug-in connections on fuel level sensor.

Carrera 2 - USA:

Carrera 2 - Row:

NOTE: Mark the installation position with a paint marker before removing the fuel level sensor.

2. Unscrew cap on fuel level sensor. Use special tool for this, depending on the version (USA - RDW).

Figure 1: Carrera 2 - USA variant:

Figure 2: Carrera 2 - Row variant:

- Figure 1 - Socket wrench 3217.
- Figure 2 - Lug wrench P 9731.

3. Carefully pull fuel level sensor out of the fuel tank. Loosen plug connections and remove sensor completely

Electric plug connection on Carrera 2.

Plug-in couplings on fuel lines for fuel level sensor on Carrera 2.

Removing sensor - Carrera 4

DANGER:
Risk of fire from escaping fuel.
- Danger of fatal injury and damage to property.
- Observe basic safety instructions when working on the fuel system.
- Secure working area.

NOTE: Watch out for emerging fuel when disconnecting fuel lines. Place a clean cloth on the connection point, then loosen the connection.

Tool:

Flange of Carrera 4 - USA version.

Flange of Carrera 4 - Row version.

- Item 1 - Pressure line
- Item 2 - Vent line
- Item 3 - Electric combination connector

NOTE: Mark the installation position with a paint marker before removing the fuel level sensor.

2. Screw cap off the fuel level sensor using special tool lug wrench P 9731.

3. Carefully pull fuel level sensor out of the fuel tank and loosen all plug connections.

Carrera 4 variant

4. Remove sensor from the fuel tank.
5. Remove seal.

Installing fuel level sensor

Installing sensor - Carrera 2

NOTE: Replace seal for fuel level sensor.

1. Push new seal on sensor.
2. Insert fuel level sensor into the fuel tank. Ensure that sensor mechanism has sufficient clearance.

3. Plug in all plug connections on the inside of the sensor.
4. Place sensor in installation position. Fit relevant cap.

Carrera 2 - Row:

5. Tighten plastic cap using special tool socket wrench 3217. Tightening torque: 70 (52 ft.lb.) Nm.

Carrera 2 - USA:

6. Tighten metal cap using special tool lug wrench P 9731. Initial tightening: 60 (44 ft.lb.) Nm.

7. Then tighten further until the notch on the cap is between the white marking lugs on the tank flange.

8. Connect plug connections on fuel level sensor. The plugs must engage audibly; check that they are seated securely.

Installing sensor - Carrera 4

NOTE: Replace seal for fuel level sensor.

1. Insert new sealing ring on the flange.
2. Insert fuel level sensor into the fuel tank. Ensure that sensor mechanism has sufficient clearance.

3. Plug in all plug connections on the inside of the sensor.

4. Insert fuel level sensor into the positioning groove.
5. Screw on metal cap and tighten using special tool lug wrench P 9731. Initial tightening: 60 (44 ft.lb.) Nm.

6. Then tighten further until the notch on the cap is between the white marking lugs on the tank flange.

7. Connect plug connections on fuel level sensor. The plugs must engage audibly; check that they are seated securely.

- Item 1 - Pressure line
- Item 2 - Vent line
- Item 3 - Electric combination connector

Subsequent work

Subsequent work - Carrera 2
1. Install carrier plate for battery. Tighten four hexagon nuts. Tightening torque: 23 (17 ft.lb.) Nm.
2. Install battery.

Subsequent work - Carrera 4
1. Install cover for tank flange. Position and tighten four cap nuts and washers. Tightening torque: 10 (7.5 ft.lb.) Nm.
2. Install luggage compartment cover.
3. Connect ground lead to battery.