Fuel Gauge Sender: Service and Repair

NOTE: There are certain differences when replacing the fuel level sensor in 4-door and 5-door models. Start the procedure for the 4-door model with DDL1 while skipping steps DDL4,5 and 6, and for the 5-door model start with DDL4.

DDL1 Removing 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.

DDL2 Disconnecting Connector:





- Disconnect fuel level sensor and separate wiring.

DDL3 Removing Covers:





- Remove covers over fuel level sensor and fuel pump (FP).

DDL4 Removing Hatches and Panels:





- Fold down right rear seat backrest.
- Remove the rear hatch and both side panels.
- Fold up the front hatch, unscrew the two screws on each side, pull the hatch backward and lift up.
- Fold back cargo compartment carpet to the left.

DDL5 Disconnecting Connector:





- Disconnect fuel level sensor connector, SB, and separate wiring.

DDL6 Removing Covers:





- Remove plastic cover over fuel level sensor cover. Put to one side.
- Remove covers over fuel level sensor and fuel pump (FP).

DDL7 Removing Fuel Level Sensor:

Wrench 999 5486:

- Pull fuel level sensor cable out through the hole by the fuel level sensor.
- Remove the plastic fuel level sensor collar. Use tool 999 5486-9.
- Lift up the fuel level sensor.
- Remove gasket.

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

DDL8 Installing 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 fuel level sensor with electrical connections along the car.
- Tighten nut to 30 Nm (22.1 ft.lb).





- Turn 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 fuel level sensor.
- Reinstall covers, hatches and cargo compartment carpet in reverse order. Check that no cables are trapped.