Fuel Gauge Sender: Service and Repair

16 12 000 Removing And Installing/Replacing Sensor For Fuel Gauge

Special tools required:







Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.







IMPORTANT:
Ensure adequate ventilation in the workbay.
Avoid skin contact (wear gloves).
Ensure absolute cleanliness when performing repair work on the open fuel system. Dirt contamination in the fuel tank may impair driving or may even result in vehicle breakdown.







Necessary preliminary tasks:
- Draw off fuel.
- Remove rear seat bench.







Fold both floor trims (1) to the side.
Unfasten screws (2).
Remove cover for service opening (3).







Disconnect plug connection (1).
Disconnect fuel line (2).
If necessary, disconnect fuel line for auxiliary heating.

Installation note:
Check gasket (3), replace if necessary.







Fit special tool 16 1 190 with wide crank web (1) towards rear onto locking ring (2).
Connect special tool 33 5 070 with reversible ratchet head 1/2 " (3) and position on special tool 16 1 190.
Release locking ring (2) in counterclockwise direction.







Lift out flange cover.
Disconnect plug connection (1).

Installation note:
Replace sealing ring (2).







NOTE: Picture does not show the fuel tank outer skin.

Move retaining tabs (1) in direction of arrow through service opening.
Unclip fuel level sensor (2) in the direction of the arrow vertically towards the top.

Installation note:
Insert fuel level sensor (2) into the bracket from the top and press downwards onto the limit position.
The fuel level sensor (2) must engage audibly.







NOTE: Picture does not show the fuel tank outer skin.

Detach cable (1) of the fuel level sensor from the bracket (2).

Installation note:
Ensure correct routing of cable (1).

Unclip the plug connector of the fuel level sensor (3) from the plug connector of the left installation unit.
Remove fuel level sensor.