Fuel Level Sensor: Service and Repair
WM 201519 Removing and installing fuel-level sensor
Tools
Technical values
Preliminary work
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
Information
The fuel filter is integrated in the right connection unit, while the pressure regulator is in the fuel pump (delivery unit).
This description relates to all three fuel-level sensors.
Piping diagram in approximate installation position (components removed on workshop floor)
1. Drain the tank if necessary. -> 2010EN Draining and filling the fuel tank (draining and filling in fuel) Procedures
1.1. The fuel tank should be drained before opening the flange under the rear seat. If the displayed fuel level is less than the reserve, there is no need to drain the tank.
1. Remove (pull off) all covers -1, 2 and 3- in the bodyshell opening.
1.1. Loosen and fold up the rear seat and carpet in the luggage compartment. -> 724819 Removing and installing rear seat - section on "Removing" 724819 Removing and installing rear seat
Covers and bodyshell openings
2. Release and disconnect the top connections on the flanges (release flange rings).
3. Remove flanges using a wrench T10202. => Special tool on flange ring
Special tool on flange ring
4. Lift up the flange and disconnect all connections. Mark the plug connections with adhesive tape while doing this (this makes installation easier).
Removing fuel-level sensor
1. Remove fuel-level sensor in the vent flange.
1.1. Lift up the tank vent flange => Raised flange.
Raised flange
1.2. Lift up the left flange in direction of travel -2- and disconnect the cable for the vent flange. Pull the cable for the vent flange -1- through and remove it. Replacement part only available complete with flange, fuel-level sensor and cables.
Piping diagram in approximate installation position (components removed on workshop floor)
2. Remove the left fuel-level sensor.
2.1. Lift up the left flange in direction of travel -2- and disconnect the cable. Release the left fuel-level sensor at the floor holder -3- and remove it. Replacement part is identical to the replacement part for the right side.
Piping diagram in approximate installation position (components removed on workshop floor)
Sucking jet pump holder 2 and fuel-level sensor 1
Cable connection for fuel-level sensor
3. Remove the right fuel-level sensor.
3.1. Lift up the right flange in direction of travel -10- and disconnect the cables and lines. Release the right fuel-level sensor at the floor holder -9- and remove it. Replacement part is identical to the replacement part for the left side.
Piping diagram in approximate installation position (components removed on workshop floor)
Sucking jet pump holder 2 and fuel-level sensor 1
Installing fuel-level sensor
1. Installation is carried out in reverse order. During installation, make sure that the lines you marked during removal are routed and fitted again correctly. Check that all locking mechanisms are seated securely by pulling on them.
2. For the fuel-level sensor in the vent flange -1- , pull the cable -between 1 and 2- through the tank using a piece of wire.
Piping diagram in approximate installation position (components removed on workshop floor)
3. Replace seals when refitting the flanges. => Seals on flanges
Seals on flanges
4. Fit the flanges using a wrench T10202. => Special tool on flange ring => Tightening torque: 110 Nm (81.5 ftlb.)
Special tool on flange ring
Subsequent work
1. Fit all covers -1, 2 and 3- in the bodyshell opening.
Covers and bodyshell openings