Fuel Level Sensor 3

Fuel Level Sensor 3

Special tools, testers and auxiliary items required

• Pry Lever - Rmv Outside Mirror (80 - 200)

• Wrench (T10202)

Removing

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

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

- Slide the seats forward as far as possible. Then fold the backrest forward.

CAUTION!
Danger due to escaping fuel.

• To prevent large quantities of fuel from escaping when removing fuel level sensor 3 (G237), fuel tank may only be a maximum of 1/4 full.

- Empty the fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

CAUTION!
Risk of destroying electrical components when battery is disconnected.

• Observe measures when disconnecting battery.

- With the ignition switched off, disconnect the battery ground (GND) cable - arrow -.





- Open fuel filler flap briefly and then close again.

R8 Coupe

- Remove the rear shelf.

- Remove side trim panel.

- Remove the positive wire - 4 -.





- Disconnect the electrical connectors - 3 - on the connector station and remove the connector station from the control module bracket and lay it to the side.

- Remove the right rear relay and fuse carrier from the control module bracket and lay it aside - arrows -.

• Ignore - 1, 2 and 5 -.

- Disconnect the control module electrical connectors and remove the control module bracket - arrow - from the vehicle.





- Press the electrical wiring harness off the rear bulkhead using (80 - 200) and free it up.

R8 Spyder

- Remove the cover module.

All Vehicles

- Fold the insulation mat over the connection seal cover.

- Remove bolts - 1 through 4 - and remove the left locking flange cover.





- Disconnect the electrical connector - arrow - on the left locking flange.





CAUTION!
Risk of injury from fuel.

• To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

- Disconnect the fuel lines - 1, 2, 3 - on the left locking flange by pressing the release buttons.

• Depending on the version, there may be 2 instead of 3 lines.

CAUTION!
Danger due to escaping fuel.

• To prevent large quantities of fuel from escaping when removing fuel level sensor 3, fuel tank may only be a maximum of 1/4 full.

- Disconnect the left locking flange locking rings using the (T10202).





- Disconnect the fuel lines - 1, 2, 3 - on the inner side of the left locking flange by pressing the release button.





- Disconnect the electrical connector - 4 - and - 5 - and remove the locking flange and sealing ring.

• Fuel level sensor 3 is illustrated without the fuel tank.

- Reach into the fuel tank and remove the fuel level sensor 3 by pressing locking tabs at the same time - 1 - and - 2 - out of the baffle house guide - arrow -.





• When removing, be sure not to bend floater arm of fuel level sensor 3.

Installing

• Tightening specifications, refer to => [ Fuel Level Sensor Assembly Overview ] Fuel Level Sensor Assembly Overview, => [ Locking Flange Cover - Tightening
Specifications ] Fuel Level Sensor Assembly Overview.

Installation is in reverse order of removal, note the following:

• Replace sealing ring.

• When inserting, be sure not to bend floater arm on fuel level sensor 3.

- Install the fuel level sensor 3 in the guide until it audibly clicks.

- Install a new dry locking flange sealing ring.





CAUTION!
Risk of leaking.

• When inserting sealing flange, sealing ring must not be damaged or crushed.

- Bring the locking flange into the installation position.

• The tab - 2 - on left locking flange faces toward the drive direction (between the 11- and 11 o'clock positions) and must lie between tabs - 1 - and - 3 - on the fuel tank.

- Tighten the locking ring.





- Fuel Tank, Checking for Leaks. Refer to => [ Fuel Tank System, Checking for Leaks ] Fuel Tank System, Checking For Leaks

- Inspect the seal - 1 - on the locking flange covers for damage.





- If necessary, replace the seal.

- Install the connector station and the right, rear relay and fuse panel.

R8 Spyder

- Install the cover module.

All Vehicles

- Connect the battery and observe safety precautions after connecting battery.