Fuel Level Sensor: Service and Repair

Fuel Level Sensor 2 -G169-, Removing And Installing

Special tools and equipment







- Wrench for fuel tank sender unit 3087
- To remove Fuel gauge sender II, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary.


WARNING: Observe safety precautions when disconnecting the battery.


- With ignition switched off disconnect battery ground strap.
- Open fuel filler cap briefly, then close it again.
- Remove rear seat bench.







- Detach cover for flange (left side) -arrows-.







- Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle).


WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.







- Disconnect fuel return pipe -arrow- from flange (left side of vehicle).


CAUTION: Fuel gauge sender II flange must only be removed with the fuel tank not more than 1/4 full. Otherwise a great amount of fuel flows out.







- Remove locking ring (left side of vehicle) using wrench for fuel gauge sender unit 3087.
- Carefully pull flange with fuel gauge sender II a short distance out of fuel tank opening together with seal.







- First pull fuel line -1- out of fuel tank.
- Swivel flange -2- with fuel gauge sender II -3- and suction jet pump -4- out of fuel tank opening.


NOTE: Take care not to bend the arm of the float when removing sender II.


- Unclip suction jet pump from flange with fuel gauge sender II.







- Press release catches -arrows- and disconnect fuel line at Y-connector.
- Remove sealing flange with fuel gauge sender II.

Installing
Install in reverse sequence; note the following points:
- Fit new seal for flange of fuel gauge sender II in fuel tank opening (seal should be dry).







- Note fitting position of flange of fuel gauge sender II:
- Lug -2- on flange must be between tabs -1- and -3- on fuel tank.


NOTE: Arrow points in direction of travel.







- Tighten locking ring (145 Nm).
- Observe safety precautions after connecting the battery.

Tightening torques

Component Nm
Locking ring for fuel delivery unit 145
Battery terminal to terminal post 6