Replacement Of Fuel Level Sensor
Replacement of fuel level sensor
Special tools:
999 5486 KEY 999 5486 Key
Preparations
5-door car
Raise the front floor hatch.
Remove the four screws in the floor hatch.
Pull the floor hatch rearward.
Fold aside the mat and lower the rear seat.
4-door car
Fold the right-hand rear seat forward.
Remove:
- the cargo compartment mat and fold aside the right-hand wheel housing panel (on certain variants with hard panels, it must be removed).
- the cable and connector holder. This sits in two clips above the cover for the fuel level sensor.
- the covers for the fuel pump and fuel level sensor.
- the protective casing over the fuel level sensor (if fitted). If the protective casing is difficult to remove, slightly loosen the tank straps and filler pipe so as to adjust the position of the tank.
Warning! The tank must be supported by a transmission jack or similar before the tank strap bolts are removed.
Marking with tape
Before the old fuel level sensor is removed, a gauge should be placed as shown in the illustration.
Use gauge, part number 9463238.
Place a piece of tape on the body under the gauge openings, see arrows.
Mark the tape by looking through the openings of the gauge.
Routing the wiring harness
Loosen and separate the connector for the fuel level sensor.
Bend the fuel level sensor's wiring harness over to the right-hand side.
Attach a length of string or the like to the connector for the fuel level sensor. See illustration.
Carefully pull the wiring harness and connector through the fuel level sensor's hole.
Note! Leave the string in place so that the connector for the new fuel level sensor can be pulled back.
Removing the fuel level sensor
Caution! Reinstall the fuel level sensor's nut back on the tank's threads, if the new fuel level sensor is not installed immediately. Otherwise the tank's threads could be deformed.
Loosen and remove the nut using special tool 999 5486 KEY 999 5486 Key.
Carefully pull the fuel level sensor up halfway and let the petrol run out.
Caution! Make sure that no fuel is spilled when the fuel level sensor is removed.
Remove the fuel level sensor and the old gasket.
Fitting a new fuel level sensor
Note! The fuel level sensor's arrow marking should point between the markings on the tape.
Fit a new gasket for the fuel level sensor
Lubricate the sliding surface of the nut on the fuel level sensor so as to avoid the fuel level sensor turning when the nut is tightened. Use Vaseline or the like.
Carefully lower the new fuel level sensor into place.
Fixing the fuel level sensor
Align the fuel level sensor as in the illustration.
Fit the nut and tighten to a torque of 30 Nm.
Use gauge, part number 9463238.
Check the installation of the fuel level sensor with a gauge, as in the illustration.
Routing the wiring harness
Attach the string from the wiring harness to the new fuel level sensor.
Carefully pull the fuel level sensor's wiring harness back into position.
Check that the fuel level sensor's wiring harness has returned to the left-hand side of the vehicle.
Reassemble the connector and fit it back in the holder.
Fitting components
Refit:
- the protective casing over the fuel level sensor (if removed). Tighten the bolts of the tank straps (if loosened) to a torque of 25 Nm.
- both covers.
- the cable holder with clips.
- the panels and floor mats in the cargo compartment.
Check the functionality of completed work.