Fuel Gauge Sender: Service Precautions

Fuel Supply System


When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all lines and wires in their original locations.

• For example, fuel lines, hydraulic lines, Evaporative Emission (EVAP) lines, coolant, refrigerant, brake fluid and vacuum.

• Ensure sufficient clearance to all moving or hot components.

• The fuel or fuel lines in the fuel system can become very hot (danger of scalding)!

• In addition, the fuel system is under pressure! Before opening the system, place a cloth around the connection area and release pressure by carefully loosening the connection!

• Wear protective goggles and protective gloves when working on the fuel system!


Remember, the fuel pump will turn on when a door is opened, if the battery is connected. Fuel may leak out when the system is open.

Always observe the following when removing and installing the fuel level sensor or the fuel pump from a full or partially filled fuel tank.

• Before starting work, place a extracting hose from an exhaust extractor that is switched on near the fuel tank opening. This will extract the fuel vapors. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m3/h can be used.

• Prevent fuel from contacting skin! Wear fuel resistant gloves!


Very hot fuel can burn your skin.

• In extreme cases the temperature of the fuel lines and/or the fuel can go up to 100 °C (212 °F). Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.

• Wear safety gloves

• Wear protective eyewear.

There is a risk of injury because the fuel is under high pressure.

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


The fuel lines are under pressure. Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.


Do not damage the fuel hoses in the engine compartment.

• The coupling must audibly engage when locking.

• Note the color coding when installing the coupling, refer to => [ Coupling Allocation: ] Coupling, Disconnecting!

• Pull on the coupling to make sure it is secure.

• Disconnecting the couplings. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.