Fuel Level Sensor: Service and Repair

WM 201519 Removing and installing fuel level sensor - Turbo

Tools





Technical values






Preliminary work

1. Place protective covers on the vehicle to avoid damaging the vehicle.
2. Disconnect the battery.
=> 2706IN Work instructions after disconnecting the battery
3. Remove luggage compartment cover.
=> 700519 Removing and installing front luggage compartment trim panel - section on "Removing"
4. Remove cover for access to the fuel level sensor.
4.1. Screw off four M6 nuts -2- and remove the cover.
4.2. Check seal and replace it if necessary.






Cover for access to fuel level sensor

Removing fuel level sensor

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 vapours.
-> Attach warning sign in a clearly visible position.

Information

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

1. Connect plug connections on the fuel level sensor.
1.1. USA variant:





Fuel level sensor - 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 plug connection -3-.
1.2. RoW variant:





Fuel level sensor - RoW

1.2.1. Release and pull off plug-in couplings for fuel lines -1- and vent line -2-.
1.2.2. Release and pull off multiple plug connection -3-.
2. Screw metal catch off the fuel level sensor using special tool lug wrench P 9731.





Lug wrench P 9731 - fuel level sensor

3. Remove fuel level sensor.
3.1. Carefully pull fuel level sensor out of the fuel tank.
3.2. Release and pull off plug-in coupling for the fuel line -1- on the fuel level sensor.





Fuel line on fuel level sensor

Press locking lugs and pull off the plug-in coupling.
3.3. Release and unplug electric plug connection on the fuel level sensor -1-.





Multiple connector for fuel level sensor

3.3.1. Disconnect the two housing halves (yellow/blue) -2, 3- of the multiple plug connection.
3.4. Carefully remove the fuel level sensor.

Installing fuel level sensor

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.
Make sure that the sensor mechanism has sufficient clearance.
1.3. Connect electric plug connection.





Multiple plug connection for fuel level sensor

1.3.1. Join the two housing halves (yellow/blue) -2, 3- of the multiple plug connection.
1.3.2. Fit and engage the two-piece multiple plug connection on the fuel level sensor -1-.
1.4. Connect the plug-in coupling for the fuel line -1- to the fuel level sensor.





Fuel line on fuel level sensor

The plug-in coupling must lock with an audible click.
1.5. Insert the fuel level sensor and fit and tighten the metal catch.





Inserting fuel level sensor - RoW

1.5.1. RoW/USA variant: Place sensor in installation position.
Installation is described for the RoW fuel level sensor. The procedure for the USA variant is the same.
2. Tighten the metal catch using special tool lug wrench P 9731.





Lug wrench P 9731 - fuel level sensor

3. Then tighten further until the notch -1- on the cap is between the white marking lugs -2- on the fuel tank flange.





Tightened cap position on fuel level sensor

4. Connect plug connections on the fuel level sensor.
4.1. USA variant:





Flange for fuel level sensor - USA

4.1.1. Connect and lock the plug-in couplings for the fuel line -1- and vent line -2-.
The plug-in couplings must lock with an audible click. Check that they are seated securely.
4.1.2. Fit multiple plug connection -3-.
4.2. RoW variant:





Flange for fuel level sensor - RoW

4.2.1. Connect and lock the rapid-action couplings for the fuel line -1- and vent line -2-.
The plug-in couplings must lock with an audible click. Check that they are seated securely.
4.2.2. Fit multiple plug connection -3-.

Subsequent work

1. Install cover for access to the fuel level sensor. Fit and tighten four M6 nuts -2-.





Cover for access to fuel level sensor

=> Tightening torque: 10 Nm (7.5 ftlb.).
2. Install luggage compartment cover.
=> 700519 Removing and installing front luggage compartment trim panel - section on "Installing"
3. Connect the battery.
=> 2706IN Work instructions after disconnecting the battery
4. Carry out a function test and check the system for leaks.
5. Remove protective covers from the vehicle.
6. Calibrate fuel level sensor.
=> 2015IN Calibrating fuel-level sensor system