Fuel Gauge Sender: Service and Repair

Removing And Installing Fuel-level Sensor


Tools







Technical values







Preliminary work

WARNING:
- Toxic substances
- Danger of poisoning or suffocation
- Ventilate the work area well.
- Never ingest or inhale.
- Read specific information on the Hazard Sheet.
- Wear personal protective gear.

WARNING:
- Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapors.
- Attach warning sign in a clearly visible position.

INFORMATION:
- The fuel filter is integrated in the right connection unit, while the pressure regulator is in the fuel pump (delivery unit).
- This description relates to all three fuel-level sensors.







1. Drain the tank if necessary.
1.1. The fuel tank should be drained before opening the flange under the rear seat. If the displayed fuel level is less than the reserve, there is no need to drain the tank.

1. Remove (pull off) all covers -1, 2 and 3- in the bodyshell opening.







1.1. Loosen and fold up the rear seat and carpet in the luggage compartment.

2. Release and disconnect the top connections on the flanges (release flange rings).







3. Remove flanges using a wrench T10202. -> Special tool on flange ring
4. Lift up the flange and disconnect all connections. Mark the plug connections with adhesive tape while doing this (this makes installation easier).

Removing fuel-level sensor

1. Remove fuel-level sensor in the vent flange.







1.1. Lift up the tank vent flange -> Raised flange.







1.2. Lift up the left flange in direction of travel -2- and disconnect the cable for the vent flange. Pull the cable for the vent flange -1- through and remove it. Replacement part only available complete with flange, fuel-level sensor and cables.

2. Remove the left fuel-level sensor.













2.1. Lift up the left flange in direction of travel -2- and disconnect the cable. Release the left fuel-level sensor at the floor holder -3- and remove it. Replacement part is identical to the replacement part for the right side.

3. Remove the right fuel-level sensor.










3.1. Lift up the right flange in direction of travel -10- and disconnect the cables and lines. Release the right fuel-level sensor at the floor holder -9- and remove it. Replacement part is identical to the replacement part for the left side.

Installing fuel-level sensor

1. Installation is carried out in reverse order. During installation, make sure that the lines you marked during removal are routed and fitted again correctly. Check that all locking mechanisms are seated securely by pulling on them.







2. For the fuel-level sensor in the vent flange -1-, pull the cable -between 1 and 2- through the tank using a piece of wire.







3. Replace seals when refitting the flanges. -> Seals on flanges







4. Fit the flanges using a wrench T10202. -> Special tool on flange ring -> Tightening torque: 110 Nm (81.5 ftlb.)

Subsequent work







1. Fit all covers -1, 2 and 3- in the bodyshell opening.