Fuel Level Sensor (G)
Fuel Level Sensor (G)
Special tools, testers and auxiliary items required
• Wrench (T10202)
• Scissors
Removing
- Follow all safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.
- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] .
Danger due to escaping fuel.
• To prevent large quantities of fuel from leaking from the fuel level sensor when removing, the fuel tank may only be a maximum of 1/4 full.
- Empty the fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.
- Move the right front seat all the way forward.
- Remove the rear bench seat or the lower seat frame/rear seat backrest.
Danger of causing damage to other electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Disconnect the Ground (GND) cable - 2 - from the battery.
- Cut the insulation mat near the locking flange cover along the perforation with scissors and fold it to the side.
- Remove the bolts - arrows - and remove the locking flange cover - 1 -.
- Disconnect the connectors - 1 and 2 - on the locking flange.
There is a risk of injury because the fuel is under high pressure.
• To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Disconnect the fuel line - 2 - at the locking flange by pressing the release button.
• Disregard - 1 -
Danger due to escaping fuel.
• To prevent large quantities of fuel from leaking from the fuel level sensor when removing, the fuel tank may only be a maximum of 1/4 full.
- Remove the locking ring using the (T10202).
- Remove the locking flange - 1 - through the opening in the fuel tank.
- Remove the seal - 4 - through the opening in the fuel tank.
- Disconnect the fuel line - 2 - from the locking flange.
- Disconnect the connectors - 3 and 5 -.
- Reach into the fuel tank, push the catch - 1 - in direction of - arrow A - and release the fuel level sensor.
- Remove the fuel level sensor - 2 - from the mount in the baffle housing - arrow B -.
- Swivel the fuel level sensor - 1 - to the side and rotate it upward 90° by its own axle - arrow A -.
- Carefully remove the fuel level sensor, with its electric wire, from of the fuel tank - arrow B -.
• When removing, be sure not to bend the floater arm of fuel gauge.
Installing
Install in reverse order of removal. Note the following:
• Tightening specification, refer to => [ Fuel Delivery Unit Overview ] Fuel Delivery Unit Overview
• Replace seal.
• Make sure the fuel hoses are secure.
• When removing, be sure not to bend the floater arm on the fuel level sensor.
- Insert the fuel level sensor - 1 - in the fuel tank.
- Position the guide - 2 - on the fuel level sensor on the edge - 5 - of the baffle housing - arrow A -.
- Push the fuel level sensor - 3 - all the way into the mount - 1 - on the baffle housing - arrow B -.
- Press the tab - 4 - on the fuel level sensor until it engages into the baffle housing.
- Connect the connectors - 3 and 5 - and make sure they engage.
- Install the fuel line - 2 - until it audibly latches on the locking flange.
- Install the new locking flange seal - 4 -. The seal must dry.
- Insert the locking flange - 1 - into the fuel tank.
- Bring the locking flange into the installation position.
Risk of leaking.
• When inserting sealing flange, sealing ring must not be damaged or crushed.
• The tab - 2 - on the right locking flange must be located between the tabs - 1 and 3 - on fuel tank.
• The arrow on the locking flange must point in direction of travel.
- Attach the fuel lines so that they audibly latch.
- Connect the connectors and make sure they are secure.
- Install the right locking flange cover. Refer to => [ Locking Flange Cover - Tightening Specifications ] Fuel Delivery Unit Overview.
- Install the rear bench seat or the lower seat frame/rear seat backrest.
- Connect the battery. Be sure to read the procedures after connecting the battery.