Fuel Level Sensor 2

Fuel Level Sensor 2

Special tools, testers and auxiliary items required

• Union nut tool (T40068 A)

Removing

Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] [1][2]Fuel Injection System.

CAUTION!
Danger due to escaping fuel.

• To prevent large quantities of fuel from escaping when removing fuel level sensor 2 , fuel tank may only be a maximum of 1/4 full. Drain fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.

CAUTION!
Risk of destroying electrical components when battery is disconnected.

• Follow the instructions when disconnecting the battery.

- Switch off ignition.

Sedan:

- Fold the luggage compartment floor upward.

Wagon:





- Remove luggage compartment cargo floor - 1 - and spare wheel cover - 2 -.

All:





- Release the retaining clips - arrows - with a screwdriver - 2 - and remove the cover - 1 -.

- Disconnect ground (GND) strap at battery ground (GND) terminal - arrow -.





- Remove rear seat bench.





- Unbolt cover for left locking flange - arrows -.







CAUTION!
Danger due to escaping fuel.

• To prevent large quantities of fuel from escaping when removing fuel level sensor 2, fuel tank may only be a maximum of 1/4 full.

- Remove the left union nut with the (T40068 A) - arrow -.

• The plastic catch on the threaded ring breaks off when the union nut is loosened.

- Carefully pull the fuel level sensor 2 - 1 - and suction jet pump - 2 - partially out of the fuel tank opening.





• When removing, be sure not to bend floater arm of fuel level sensor 2.

- Unclip the suction jet pump from the locking flange.





- Separate the electrical connector - 1 -.

- Release retaining tabs - arrows - with a screwdriver and remove the fuel level sensor 2.

Installing

• Assembly overview, refer to => [ Fuel Delivery Unit and Fuel Level Sensor Assembly Overview ] Fuel Delivery Unit and Fuel Level Sensor Assembly Overview.

• Tightening specifications, refer to => [ Fastener Tightening Specifications ] Fuel Supply System - Fastener Tightening Specifications.

Installation is performed in the reverse order of removal, noting the following:

• Always replace seal and union nut.

- Insert fuel level sensor 2 in guides on locking flange and press in until it engages.

- Connect the electrical connection and check that it is securely engaged.

- Clip the suction jet pump - 3 - to the locking flange - 2 - so that it is audibly engaged.





- Check whether fuel delivery line is connected to suction jet pipe with at least 3 cable ties.

• When inserting, be sure not to bend floater arm on fuel level sensor 2.

- Carefully insert fuel level sensor 2 in fuel tank opening.

- Slide the new gasket - 1 - over the sealing flange and insert it in the groove on the fuel tank.

- Slide the union nut - 1 - over the left arm and press the sealing flange forcefully - 2 - into the installation position with the left hand - arrow -.





• The tab - 4 - on locking flange must lie between tabs - 3 - and - 5 - on threaded ring.

- With the right hand, slide the union nut - 1 - off the left arm while continuing the press the sealing flange - 2 - down forcefully with the left hand - arrow -.





- Position the union nut - 1 - with the right hand so the double ridge - 5 - on the ribbing lies over the tab - 3 - on the sealing flange (approximately the 10 o'clock position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it - 4 -.

- Continue pressing the sealing flange down forcefully.





- Rotate the sealing ring approximately 390° with the right hand until the double ridge - 1 - is in the 12 o'clock position while continuing to press the sealing flange down forcefully with the left hand.







CAUTION!
There is a risk of the locking flange threaded connection leaking.

• Press the locking flange down firmly when tightening the union nut so it does not rotate too.

- Tighten the left sealing flange union nut with the (T40068 A).

• Verification: The double ridge - 1 - must now be between the 5 o'clock and 6 o'clock positions.





- Install rear seat bench.

- Connect battery. Observe safety precautions after connecting battery.

- After installing the fuel level sensor 2, fill the vehicle with at least 5 liters of fuel.