Replacing Sensor For Fuel Level Gauge (Left)

Removing And Installing/replacing The Sensor For The Fuel Level Gauge (left)

CAUTION:
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.

Draw off approx. 10 liters of fuel from full fuel tank. Do not run the engine when performing this task.









Remove rear seat bench.







Detach rubber plug above sensor unit on left.
Fold back rubber mat.

CAUTION: Do not damage gasket.







Release screws (1) and fold back metal cover.







Unlock plug connection (1) and disconnect.
Force off hose with a clamp.
Release hose clamp (2) and carefully detach hose. Do not damage connecting piece when doing so.

Installation:
Release hose clamp.
Tightening torque
7AZ Hose clamps 10 - 16 mm dia. 2 Nm







Release screw cap with special tool 16 1 020.

Installation:
Replace rubber gasket.
Tighten down screw cap to specified torque.
Tightening torque
2AZ Sealing ring for fuel tank (service aperture, fuel level sensor, pump unit)
Locking ring (metal)
E39 / E52 / E53 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 return. 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 be clearly heard and felt to engage toothed segment (4) on fuel tank.

CAUTION: Do not bend sensor.







Carefully pull fuel level sensor upwards until access is gained to suction jet pump connection.

Press retaining lugs (1) inwards.
Carefully pull off connection (2) of suction jet pump towards bottom.
Carefully withdraw fuel level sensor, tilted in direction of travel towards left.

Installation:
1. Retaining lugs (1) must be completely snapped into place.
2. Replace rubber seal on fuel level sensor.
3. Fit rubber seal over fuel level sensor flange.
4. Before pressing fuel level sensor into tank opening, detach rubber seal from flange and insert into tank opening.

Installation:







Replace O-ring (1) on fuel level sensor. Before fitting, apply a light coat of engine oil to O-ring.
Check that O-ring is correctly seated when installed.
Connection of suction jet pump is transparent.

CAUTION: Comply with the following installation instruction without fail.

Installation:







When installing fuel level sensor, comply with the following without fail.
1. Insert fuel level sensor flange (1) horizontally into tank opening so that sensor foot (2) is positioned vertically in recess (3) in bottom of fuel tank.
2. Press fuel level sensor flange into tank opening.
3. Fuel level sensor flange must remain in pressed-in position.
When the flange is partially pressed out, the sensor foot (2) is not in the recess (3) in the bottom of the fuel tank.
4. Line set (5) must not interlock with sensor arm (4).