FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Correction

Inspect the suction jet connection at the left side fuel level sensor and refit if necessary, to ensure the retaining clips are positively locked in position.

PROCEDURE

^ Connect the vehicle to the DISplus or the GT1.

^ Select "Diagnostics", "Instrument cluster"

^ Note the fuel level in the tank

^ Fill or siphon off the fuel to achieve a level of 15 Liters in the tank.

^ Switch off the ignition





Remove rear bench seat. Detach rubber plug above sensor unit on the left side. Fold back rubber mat.





Remove 4 screws (1) and then remove cover taking care to not damage the gasket.





Disconnect plug connection (1) and carefully detach the hose (2).





Unscrew retaining ring using tool 16 1 020.





Carefully raise the level sensor until the connection (2) for the suction jet pump is accessible. Inspect the retaining lugs (1) and ensure that they are clearly and completely visible within their respective recesses. Refit if necessary.





When reinstalling, ensure that the fuel level sensor is perfectly vertical so that the sensor foot (2) is positioned in the recess (3) at the bottom of the tank. Additional, care should be taken so that the tubing (5) does not interfere with sensor arm (4).





When reinstalling, replace the rubber gasket and ensure that the lug located on the level sensor (1) catches in the recess (2).

While retorquing the retaining ring, the engagement of the notch (3) with the toothed segment (4) will clearly be felt and heard. Tightening torque is 35 Nm. Reconnect the electrical connector and reinstall the hose using a new clamp.

When installation is complete, recheck the fuel level readings as performed in the beginning steps. Values should be the same with a permissible deviation of +/- 2 liters.