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

Removing and Installing Sensor for Fuel Level Gauge (Right) / Fuel Pump (Complete Sensor Unit)







Important!
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!

Necessary Preliminary Tasks:
Draw off fuel from fuel tank. Procedures
Remove rear sear bench.







Detach rubber plug above sensor unit on right.

Fold back rubber mat.

Important!
Do not damage gasket.







Release screws ( 1 ) and fold back metal cover.







Important!
Fuel hoses are pressurized.

Unlock 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 clamps

Tighten







Release screw cap with special tool 16 1 020.

Installation:

Replace rubber gasket.

Tighten down screw cap to specified torque.

Tightening torque to 35 Nm


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, make sure that lug ( 1 ) in opening ( 2 ) engages fuel tank.

During torque tightening, notch ( 3 ) on screw cap can clearly heard and felt to engage toothed segment ( 4 ) on fuel tank.

Important!
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.