Replacing Fuel Level Sensor (Right)/ Fuel Pump (Complete Sensor Unit)

Removing And Installing The Sensor For The Fuel Level Gauge (Right) / Fuel Pump (Complete Sensor Unit)


CAUTION:
Ensure adequate ventilation in the place of work!
Ensure absolute cleanliness when working on the open fuel tank.
Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown!


Draw off approx. 10 liters of fuel from full fuel tank. Do not run the engine when performing this task. Procedures







Remove rear seat bench.







Detach rubber plug above sensor unit on right.
Fold back rubber mat.







CAUTION
Do not damage gasket.
Release screws (1) and fold back metal cover.


CAUTION: Fuel hoses are pressurized.







Unfasten plug connection and disconnect.
Force off hose with a clamp.
Release hose clamp (1) and carefully detach hose.
Do not damage connecting piece when doing so.

Independent heating only:
Force off hose with a clamp.
Release hose clamp (2) and carefully detach hose.
Do not damage connecting piece when doing so.

Installation:
Replace hose clips.
Tightening torque, Hose clamps 10 - 16 mm dia. 2 Nm







Release screw cap with special tool 16 1 020.

Installation:
Replace rubber gasket.
Tighten down screw cap to specified torque.








Carefully raise fuel level sensor until sensor flange projects out of sealing area of tank opening.
In so doing, do not pull excessively on connecting piece of fuel feed. Risk of breakage!

Installation:
When installing fuel level sensor, ensure lug (1) locates in recess (2) on fuel tank.
When tightening to torque, notch (3) on screw cap can be heard and felt to engage in toothed segment (4) on tank.







CAUTION Do not bend sensor.


Carefully raise fuel level sensor (1) and expose spiral hose (2).
Carefully remove fuel level sensor with fuel pump from fuel tank.
Tilt components in different directions in so doing.
Carefully withdraw fuel level sensor, tilted against direction of travel, out of tank opening.


Installation:
1. Replace rubber seal on fuel level sensor.
2. Fit rubber seal over fuel level sensor flange.
3. Before pressing fuel level sensor into tank opening, detach rubber seal from flange and insert into tank opening.
4. Press fuel level sensor into tank opening.