Procedures

Replacing the fuel level sensor

Special Tools:999 5486

Preparations







5 door car
- Fold up the front floor hatch.
- Remove the four screws of the floor hatch.
- Pull the floor hatch rearward.
- Fold the mat under and lower the rear seat.

4 door car
Fold the right-hand rear seat forward.

Remove:







- the cargo compartment mat and fold the right-hand wheel house panel under (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 strap and filler pipe so as to adjust the position of the tank.

WARNING: The tank must be secured with a transmission stand or the like before the bolts of the tank strap are removed.

Marking with tape







- Before the old fuel level sensor is removed, a gauge should be placed as indicated in the illustration.
- Place a piece of tape on the body under the gauge openings.
- Mark the tape by looking through the openings of the gauge.

Drawing the cable harness







- Loosen and separate the connector to the fuel level sensor.
- Pull the cable harness of the fuel level sensor to the righthand side.
- Attach a string or the like at the connector for the fuel level sensor.
- Carefully pull the cable harness with connector through the hole of the fuel level sensor.

NOTE: Leave the string so that the connector for the new fuel level sensor can be pulled back.

Removing the fuel level sensor

CAUTION: Refit the nuts of the fuel level sensor to the tank's threads if the new fuel level sensor is not fitted immediately. The tank's threads could be deformed otherwise.







- Loosen and remove the nut using special tool 999 5486.
- Carefully pull the fuel level sensor up halfway and let the gasoline drain out.

CAUTION: Ensure that no fuel is spilled with the fuel level sensor is removed.

- Remove the fuel level sensor and the old gasket.

Fitting a new fuel level sensor







NOTE: The arrow on the fuel level sensor 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 slide the new fuel level sensor down.

Fixing the fuel level sensor







- Turn in the fuel level sensor.
- Fit the nut and tighten to a torque of 30 Nm.







- Check the installation of the fuel level sensor with a gauge.

Drawing the cable harness







- Attach the string from the cable harness to the new fuel level sensor.
- Carefully pull the cable harness of the fuel level sensor back into position.







- Check that the cable harness of the fuel level sensor has returned to the left-hand side of the vehicle.
- Reconnect the connector and fit it back in the holder.

Fitting components

Fit:
- the protective casing over the fuel level sensor (if removed). Tighten the bolts of the tank strap (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 function of completed work.