Fuel Level Sensor: Service and Repair

Fuel Pump (FP) And Filter

Level sensor, fuel tank, right-hand/fuel tank, replacing

Removal

NOTE: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

Draining the fuel system and fuel tank

Drain:
- the fuel system. See Draining the fuel system
- the fuel tank. See Draining the fuel tank.

Removing the left-hand level sensor







- the two connectors from the underneath of the left-hand level sensor
- the left-hand level sensor from the ejector on which it is positioned.

NOTE: Secure a wire in the area of the ejector.

The wire must be sufficiently long that it reaches over to the opposite side of the tank with some excess remaining to ensure that it does not slide into the tank. The wire is needed to pull the hoses and wiring back to the left-hand side of the tank after the fuel tank unit has been replaced.

Removing the right-hand level sensor/pump







- Grip the right-hand level sensor and pump holder and pinch the float so that it is held in its lowest position.

NOTE: Take care with the fuel tank.







Carefully and slowly pull up the holder. Carefully work the holder out.

Pull the hoses out from the tank without pulling up the entire wire from the right-hand hole in the tank.

NOTE: It is extremely important that the float arm is not broken or bent.

Remove the wire from the old level sensor and pump ejector.

Removing the right-hand level sensor







- the tie straps around the protective sheath, hoses and wiring
- the net protective sheath by carefully threading it off the hoses and wiring
- the tie strap under the protective sheath.







- the tie strap around the wiring above the pump
- the level sensor by pressing in the two clips and pulling upwards
- the thin pipe from the holder on the outside of the fuel tank unit
- the wiring from the holder in the fuel tank unit.

Installation

Installing the right-hand level sensor







- the new level sensor
- the wiring in the holder
- the thin pipe in the holder on the outside of the fuel tank unit
- the tie strap around the wiring above the pump.







- the tie strap under the protective sheath

NOTE: Secure the tie strap on the smooth central section of the corrugated hose.

- the protective sheath
- four tie straps around the protective sheath, hoses and wiring. Secure the tie straps on the four smooth central sections of the corrugated hose.

Installing the right-hand level sensor and pump and the left-hand level sensor in the fuel tank







- Install the wire on the new ejector for the level sensor and pump
- Insert the hoses and wiring into the tank via the right-hand tank hole
- Grip the right-hand level sensor and pump holder and pinch it so that the float is held in its lowest position
- Carefully and slowly lower the holder. Carefully work the holder into place
- Pull the wire so that the hoses and wiring end up on the left side of the tank
- Install the left-hand level sensor on the ejector
- Install the switches on the underneath of the left-hand level sensor
- Remove the wire from the ejector.

Finishing
- Install the sensor, backrest, side cushion and seat cushion. See Draining the fuel tank.