Removing and Installing / Replacing Fuel Gauge Sensor (Complete Right Sensor Unit)

16 12 000 - Removing and installing/replacing fuel gauge sensor (complete right sensor unit)





Special tools required:
- 16 1 020 16 1 020 Pin Wrench





Important!
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!





Necessary preliminary tasks:
- Draw off fuel completely from fuel tank Procedures
- Remove rear seat Rear Seat - Normal
- Remove left sensor unit Removing and Installing / Replacing Fuel Gauge Sensor (Complete Left Sensor Unit)





Fold carpet (1) forwards.

Detach insulating mat (2) above left and right sensor units at perforation and fold back towards rear. Pop out rubber plugs here.

Fold back rubber mat (2).





Important!
Do not damage gasket.

Release nuts (1) on left and right.

Fold metal cover of left and right sensor units upwards.





Important!
Fuel line is pressurized.

Catch escaping fuel in a suitable container.





If necessary, unlock and disconnect plug connection (1) of right sensor unit.

If necessary, release and disconnect hose (2) for independent heating (E60 only).





Release rotary catch of left and right sensor units with special tool 16 1 020 16 1 020 Pin Wrench.

Installation Note:
Replace rubber seal on left and right.

Tightening torque 16 14 2AZ 16 14 Fuel Pump.





Important!
Risk of breakage!

Carefully raise connecting cover. In so doing, do not pull excessively on connecting piece of fuel feed.

Installation Note:
When installing connecting cover, 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.





Secure a cable to hose pack through left service opening in tank.

The cable facilitates reinstallation of the hose pack.

Carefully remove right sensor unit from fuel tank.

Important!
Surge chamber is filled with fuel.

Drain surge chamber through upper opening (1). Catch fuel in a suitable container.

Feed hose pack out of fuel tank.





Installation Note:
The new sensor unit is supplied with a plastic cover over the hose pack.

Secure the cable pulled through the tank during removal to the eyelet on the plastic cover.

Carefully feed hose pack through fuel tank using cable.

Important!
The lines on the connection are turned to the sensor unit as the hose pack is fed in.

Turn sensor unit in the same direction of rotation and align.

It is absolutely essential to avoid kinking the hoses.

Remove the plastic cover after feeding in the hose pack.





Replacing fuel level sensor:

Unlock and disconnect plug (2).

Release catches (1) and pull fuel level sensor out of unit.