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Fuel Level Sensor: Service and Repair


WM 201519 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.
=> 2706IN Work instructions after disconnecting the battery.
=> 270619 Removing and installing battery - section on "Removing".
3. Remove carrier plate for battery.





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.
=> 2706IN Work instructions after disconnecting the battery.
3. Remove luggage compartment cover.
=> 700519 Removing and installing trim panel for front luggage compartment - section on "Removing".
4. Remove cover for tank flange.





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, => 2001AW Basic safety instructions when working on the fuel system.
-> Secure working area.

Tools:

Tool for RoW variant.





Socket wrench 3217 - fuel level sensor on C2

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





Lug wrench P 9731 - fuel level sensor on C2 USA and all C4s

Information

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

Information

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:





Flange of fuel level sensor on C2 - USA

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:





Flange of fuel level sensor on C2 - USA

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:





C2 cap/USA variant

Lug wrench P 9731
Original position of cap.
2.2. Figure 2: Carrera 2/RoW variant:





Carrera 2 cap/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.





Fuel lines on fuel level sensor (underside)

Press locking lugs and pull off the plug-in coupling -1-.
3.3. Disconnect electric plug connection.





Multiple connector for fuel level sensor

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, => 2001AW Basic safety instructions when working on the fuel system.
-> Secure working area.

Tools:

Tool for all Carrera 4s.





Lug wrench P 9731 - fuel level sensor for all C4s

Information

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

Information

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 4/USA variant:





Flange of fuel level sensor on Carrera 4 - USA

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:





Flange of fuel level sensor on Carrera 4 - RoW

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.

Information

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.





Fuel lines on fuel level sensor (underside)

Press locking lugs and pull off the plug-in coupling -1-.
3.3. Disconnect electric plug connection.





Multiple connector for fuel level sensor

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.





Multiple connector for fuel level sensor

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.





Fuel lines on fuel level sensor (underside)

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.





C2 cap/RoW variant

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.





C2 cap/USA variant

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.





Tightened cap position on fuel level sensor

2. Connect plug connections on fuel level sensor.
2.1. Carrera 2/USA variant:





Flange of fuel level sensor on C2 - USA

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:





Flange of fuel level sensor on C2 - USA

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:





C2 cap/USA variant

Lug wrench P 9731
Tighten as far as the marking on the tank flange.
3.2. Figure 2: Carrera 2/RoW variant:





Carrera 2 cap/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.





Multiple connector for fuel level sensor

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.





Fuel lines on fuel level sensor (underside)

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.





Inserting fuel level sensor on C4 - RoW

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.





Tightened cap position on fuel level sensor

2. Connect plug connections on fuel level sensor.
2.1. Carrera 4/USA variant:





Flange of fuel level sensor on Carrera 4 - USA

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:





Flange of fuel level sensor on Carrera 4 - RoW

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.
=> 270619 Removing and installing battery - section on "Installing".

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.
=> 700519 Removing and installing trim panel for front luggage compartment - section on "Installing".
3. Connect ground lead to battery.
=> 2706IN Work instructions after disconnecting the battery.
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