Fuel Level Sensor: Service and Repair

Level Sensor Fuel Tank Right, Replacing

Special tools: 999 5720

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.

NOTE: To replace the level sensor for the lefthand fuel tank, see: Level sensor fuel tank left, replacing.

Preparation
Drain the fuel tank. See Fuel tank, draining.

Removing the fuel pump (FP) / level sensor







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.







Grip around the right-hand fuel pump (FP) / level sensor reservoir. Pinch the float 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 fuel pump (FP) / level sensor ejector.

Removing the level sensor

Remove:







- 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.

Installing the right-hand level sensor

Install:







- 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. 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 fuel pump (FP) / level sensor







Install the wire on the new ejector for the level sensor and pump.

Install a new O-ring.

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.

Level sensor right-hand continued
Press the right-hand level sensor down so that the fuel line connections are pointing forwards and to the right.

Check that the O-ring is not trapped.







Tighten the screw. Tighten to 60 Nm (Use tool 999 5720 ).

Install the hoses on the level sensor.

Wipe up any fuel spillage







NOTE: Check that the arrow on the cover is between the markings on the tank. If the arrow is outside the markings the fuel gauge sensor will give an incorrect value and the float may catch against the inner wall of the tank. If not: Slacken off the screw and adjust the position of the sensor. Tighten as above.

Finishing

Install on both sides:
- the wiring in the sockets on the rubber seal
- the cover over the level sensors, tighten the screws.

Connect the wiring and the connectors.

Remove the block from under the seat frame.

Install:
- the 8 seat frame screws. Tighten to 50 Nm
- the 2 seat frame screws. Tighten to 24 Nm.

Fold the carpet down.

Install:
- the center rear seat. See Upholstery backrest cushion center (second row), replacing
- the outer rear seat. See Upholstery backrest cushion outer (second row).