Removal and Replacement

Removing And Installing Fuel Level Sensor

Tools

Technical values

Preliminary work

Preliminary work - Carrera 2

1. Place protective covers on the vehicle.
2. Disconnect and remove the battery.

3. Remove carrier plate for battery.
3.1. Unscrew four M8 hexagon collar nuts -1- and remove lid.
3.2. 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.
4.1. Unscrew four M6 fastening nuts -2- , remove the four washers and lift off the lid.
4.2. Check seal for signs of damage.

Removing fuel level sensor

Removing fuel level 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.

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

1. Disconnect plug connections on the fuel level sensor.

1.1. Carrera 2/USA variant:
1.1.1. Release and pull off plug-in couplings on the fuel lines.
1.1.2. Release and pull off multiple connector.

1.2. Carrera 2/RoW variant:
1.2.1. Release and pull off plug-in couplings on the fuel lines.
1.2.2. Release and pull off multiple connector.

2. Unscrew cap on fuel level sensor.

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

Use special tool for this, depending on the version (USA - RoW).

2.1. Figure 1: Carrera 2/USA variant:
Lug wrench P 9731
Original position of cap.

2.2. Figure 2: Carrera 2/RoW variant:
Union nut tool 3217
Mark original position of cap.

3. Remove fuel level sensor.
3.1. Carefully pull fuel level sensor out of the fuel tank.

3.2. Disconnect plug-in couplings for the fuel line.
Press locking lugs and pull off the plug-in coupling -1-.

3.3. Disconnect electric plug connection.
3.3.1. Release and pull off two-piece multiple connector from the fuel level sensor -1-.
3.3.2. Separate the two housing halves (yellow/blue) -2, 3- of the multiple connector.

3.4. Carefully remove the fuel level sensor.
3.5. Replace seal.

Removing fuel level 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.

Tools:

Tool for all Carrera 4s.

1.1.1. Release and pull off plug-in couplings for fuel lines -1- and vent line -2-.
1.1.2. Release and pull off multiple connector -3-.

1.2. Carrera 4/RoW variant:
1.2.1. Release and pull off plug-in couplings for fuel lines -1- and vent line -3-.
1.2.2. Release and pull off multiple connector -3-.

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

2. Screw cap off the fuel level sensor using special tool lug wrench P 9731.
3. Remove fuel level sensor.
3.1. Carefully pull fuel level sensor out of the fuel tank.

3.2. Disconnect plug-in couplings for fuel lines on the fuel level sensor.
Press locking lugs and pull off the plug-in coupling -1-.

3.3. Disconnect electric plug connection.
3.3.1. Release and pull off two-piece multiple connector from the fuel level sensor -1-.
3.3.2. Separate the two housing halves (yellow/blue) -2, 3- of the multiple connector.

3.4. Carefully remove the fuel level sensor.
3.5. Replace seal.

Installing fuel level sensor

Installing fuel level sensor - Carrera 2

INFORMATION: Replace seal for fuel level sensor.

1. Install fuel level sensor.
1.1. Slide new seal on sensor.
1.2. Insert fuel level sensor into the fuel tank.
Check that sensor mechanism has sufficient clearance.

1.3. Connect electric plug connection.
1.3.1. Join the two housing halves (yellow/blue) -2, 3- of the multiple connector.
1.3.2. Fit two-piece multiple connector on the fuel level sensor -1-.
Check that it is seated securely.

1.4. Connect plug-in couplings for fuel lines on the fuel level sensor.
Plug in plug-in coupling -1-.
The plug-in coupling must lock with an audible click.

1.5. Fit and tighten relevant cap.

1.5.1. Carrera 2/RoW: Place sensor in installation position.
Tighten plastic cap using special tool union nut tool 3217.
- Tightening torque: 70 Nm (52 ftlb.).

1.5.2. Carrera 2/USA: Place sensor in installation position.
Tighten metal cap using special tool lug wrench P 9731.
- Initial tightening: 60 Nm (44 ftlb.).

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

2. Connect plug connections on fuel level sensor.

2.1. Carrera 2/USA variant:
2.1.1. Connect and lock plug-in couplings for fuel lines.
The plug-in couplings must lock with an audible click. Check that they are seated securely.

2.1.2. Fit multiple connector.
Check that it is seated securely.

2.2. Carrera 2/RoW variant:
2.2.1. Connect and lock plug-in couplings for fuel lines.
The plug-in couplings must lock with an audible click. Check that they are seated securely.

2.2.2. Fit multiple connector.
Check that it is seated securely.

3. Fit and screw on cap on fuel level sensor.
Use special tool for this, depending on the version (USA - RoW).

3.1. Figure 1: Carrera 2/USA variant:
Lug wrench P 9731
Tighten as far as the marking on the tank flange.

3.2. Figure 2: Carrera 2/RoW variant:
Union nut tool 3217
Tighten as far as the marking on the tank flange.

Installing fuel level sensor - Carrera 4

INFORMATION: Replace seal for fuel level sensor.

1. Install fuel level sensor.
1.1. Slide new seal on sensor.
1.2. Insert fuel level sensor into the fuel tank.
Check that sensor mechanism has sufficient clearance.
1.3. Connect electric plug connection.

1.3.1. Join the two housing halves (yellow/blue) -2, 3- of the multiple connector.
1.3.2. Fit and lock the two-piece multiple connector on the fuel level sensor -1-.

1.4. Connect plug-in couplings for fuel lines on the fuel level sensor.
Fit plug-in coupling.
The plug-in coupling must lock with an audible click.

1.5. Fit and tighten relevant cap.
1.5.1. Carrera 2/RoW variant: Place sensor in installation position.
Tighten plastic cap using special tool union nut tool 3217.
- Tightening torque: 70 Nm (52 ftlb.).

1.5.2. Carrera 2/USA variant: Place sensor in installation position.
Screw on metal cap and tighten using special tool lug wrench P 9731.
- Initial tightening: 60 Nm (44 ftlb.).

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

2. Connect plug connections on fuel level sensor.

2.1. Carrera 4/USA variant:
2.1.1. Connect and lock plug connections for fuel lines -1- and vent line -2-.
The plug-in couplings must lock with an audible click. Check that they are seated securely.

2.1.2. Fit multiple connector -3-.

2.2. Carrera 4/RoW variant:
2.2.1. Connect and lock rapid-action couplings for fuel lines -1- and vent line -2-.
The plug-in couplings must lock with an audible click. Check that they are seated securely.

2.2.2. Fit multiple connector -3-.

Subsequent work

Subsequent work - Carrera 2
1. Install carrier plate for battery.
Tighten four M8 hexagon nuts.
- Tightening torque: 23 Nm (17 ftlb.).

2. Install the battery.

Subsequent work - Carrera 4

1. Install cover for tank flange.
Fit and tighten four cap nuts and washers.
- Tightening torque: 10 Nm (7.5 ftlb.).

2. Install luggage compartment cover.
3. Connect ground lead to battery.