Fuel Level Sensor 4, Right Tubular Sensor

Fuel Level Sensor 4, Right Tubular Sensor

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

Observe safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.

Observe rules for cleanliness, Refer to => [ Clean Working Conditions ] Clean Working Conditions.

CAUTION!
• To remove the tubular sensor, the right chamber of the fuel tank may only be filled to a maximum of 1/3. Procedure to empty the fuel tank. Refer to => [ Fuel Tank, Draining ] Procedures.

CAUTION!
Observe measures when connecting battery.

- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.





- Open fuel filler flap briefly and then close again.

- Remove the luggage compartment floor mat.

• To remove and install the tubular sensor, remove vehicle tool kit and spare wheel from luggage compartment. It is then possible to sit or kneel in spare wheel well.

- Unbolt cover for right locking flange - arrows -.





- Disconnect electrical connectors - 1 - and - 2 - at right locking flange.





- Mark the fuel return line - 1 - and fuel supply line - 2 -.





CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

- Pull both lines from locking flange, by pressing the release buttons.

- Remove locking ring with Wrench (T10202).





- Pull off locking flange and remove the seal.





- Separate the electrical connectors - 1 to 3 - on the underside of the right locking flange.

• To separate the line couplings that are mentioned later in the description, pull the fuel lines out of the fuel tank opening.

• To improve clarity, the following illustration shows several components not installed.

Vehicles with MPI engine:

- Through the right fuel tank opening, separate the fuel lines - 1 - and - 2 - for the left fuel delivery unit by pressing the release buttons.





3 Right fuel delivery unit with Fuel Pump (FP) (G23)

Vehicles with FSI engine:

- Through the right fuel tank opening, separate the fuel supply lines - 1 - and - 2 - for the fuel delivery units by pressing the release buttons.





All Vehicles

- Through the right fuel tank opening, press the release buttons - arrows - and remove the fuel delivery line - 2 - and the Fuel Level Sensor 4 (G393) - 1 -.





- Swing Fuel Level Sensor 4 (G393) aside to right.

- Press down both retaining clasps - arrows - on the fuel delivery unit support.





- Pull fuel rail upward slightly and remove Fuel Level Sensor 4 (G393) at the same time.

• Note that there is still fuel in Fuel Level Sensor 4 (G393).

Installing

• Tightening specifications => [ Right Fuel Delivery Unit with Fuel Pump and Fuel Gauge Assembly Overview ] MPI Engines.

- Before installing the fuel delivery unit, pull the retaining clasps on the support upward until it engages - arrows -.





- Lift the fuel delivery unit slightly and install the Fuel Level Sensor 4 (G393).

- Carefully press the fuel delivery unit into the support until it engages audibly.

- Insert the fuel delivery line - 1 - and the Fuel Level Sensor 4 (G393) - 2 - until it engages audibly.





Vehicles with MPI engine:

- Through the right fuel tank opening, press the fuel lines - 1 - and - 2 - onto the left fuel delivery unit until they engage audibly.





3 Right fuel delivery unit with Fuel Pump (FP) (G23)

Vehicles with FSI engine:

- Reach through the right opening in the fuel tank and attach the fuel lines - 1 - and - 2 - to the fuel delivery units until they audibly engage.





All Vehicles

- Connect the electrical connectors - 1 to 3 - on the underside of the right locking flange.





- Install the new locking flange seal dry.

- Insert locking flange in fuel tank, note installation position:





• The tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

- Tighten locking ring.





- Install fuel supply line - 2 - and fuel return line - 1 - according to marking until they engage audibly.





- Connect electrical harness connectors - 1 - and - 2 - to right locking flange.





- Fasten the cover for right locking flange - arrows -.





- Connect battery. Observe safety precautions after connecting battery.