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

4 Door Models (2WD)





Remove hatches and panels:
- Fold down right rear seat backrest.
- Remove hatches and panels and cargo compartment carpet.
- Remove right wheel arch panel. In variants with a soft panel lift up the corner of the panel.





- Disconnect [1][2]fuel level sensor and separate wiring.





- Remove covers over [1][2]fuel level sensor and fuel pump (FP).

Wrench 999 5486:





Removing [1][2]Fuel Level Sensor:
- Pull [1][2]fuel level sensor cable out through the hole by the fuel level sensor.
- Remove the plastic [1][2]fuel level sensor collar. Use tool 9995486-9.
- Lift up the [1][2]fuel level sensor.
- Remove gasket.

CAUTION! Reinstall the collar, otherwise the pipe sleeve may swell making the collar hard to reinstall.

Installing [1][2]Fuel Level Sensor:









- Use a new rubber gasket.
- Lubricate the inside and top of the rubber gasket with petroleum jelly.
- Install gasket on fuel tank sleeve.
- Install [1][2]fuel level sensor with electrical connections along the car.
- Tighten nut to 30 Nm (22.1 ft.lb).
- Turn [1][2]fuel level sensor cables to the left and thread them through the hole by the fuel pump (FP).
- Put all cables together in the protective tube. Wind insulating tape around the protective tube.
- Connect [1][2]fuel level sensor.
- Reinstall covers, hatches and cargo compartment carpet in reverse order. Check that no cables are trapped.