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Fuel level sensor

Fuel level sensor

Warning

Dismantling the fuel reservoir (incl. fuel level sensor) involves work on the car's fuel system. The following points must therefore be observed in conjunction with these measures:

• Ensure good ventilation! If there is approved ventilation for extraction of fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation of the skin.

• Have a fire extinguisher suitable for flammable liquids and electrical equipment at hand! Be aware of the risk for sparks, i.e. in connection with circuit breaking, short-circuiting, etc.

• Absolutely No Smoking!

• Wear protective glasses.


Important

Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.


To remove

Important

The car must be level. There is a risk for fuel leaks if the tank is full and the rear of the car is raised for dismantling the fuel reservoir.

Protect mats with paper while dismantling the fuel reservoir as there is risk for spilling.



1. Raise the rear seat cushions and fold the carpeting out of the way.

2. Open the cover of the fuel level sensor.


3. Unplug the connectors and cut off the cable tie holding the cables together.

Important

The fuel level sensor connector must not be unplugged from the fuel reservoir lid.


4. Prise out the two wires, 3 (yellow/white) and 4 (grey/white), and remove the seal in the brown connector. Use special tool 85 80 151, subtool 09706GLA.

5. Carefully coax the check valves with fuel lines loose from the fuel reservoir (bend the yellow tabs aside with a screwdriver). The check valves are fixed to the fuel reservoir with quick-release couplings. The white represents the pressure side and is marked "Pressure". The black is the return side and is marked "Return" on the fuel reservoir. Loosen the return line and the feed line for the heater. Move them aside and secure them under the plate seam.


6. Remove the eye screw, Use 83 94 462 Spanner, fuel pump .


7. Lift the fuel reservoir (incl. fuel level sensor) until its upper portion is approx. 50 mm over the fuel tank. Then turn the reservoir clockwise approx. 80° and carefully remove the reservoir. Before lifting out the reservoir, it would be wise to cover the opening between the cover and the reservoir with a rag or paper to prevent fuel spill. Keep paper or a rag handy to catch fuel spill.


8. Transfer the fuel reservoir to a suitable container and pour off the fuel.


To fit

Note

Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting them.



1. Clean sealing surfaces.

2. Fit a new O-ring in the groove in the tank.


3. Carefully slip the fuel reservoir (incl. fuel level sensor) into the correct position. Check that the index markings on the tank and fuel reservoir match. Carefully press the reservoir down.


Important

It is essential to the function of the level sensor that the fuel reservoir (incl. fuel level sensor) be situated correctly.


4. Lubricate the threads of the cover and the top edge of the reservoir with acid-free petroleum jelly to prevent the reservoir from turning when the eye screw is tightened.

5. Fit and tighten the eye screw with 83 94 462 Spanner, fuel pump .

Tightening torque: 75 Nm (55 lbf ft)


6. Check and lubricate the O-rings on the fuel line connections with acid-free petroleum jelly and connect them to the fuel reservoir.


7. Fit the return line and the heater feed line.


8. Make sure that the yellow hooks have snapped in place over the connections.

9. Insert the pins, 3 (yellow/white) and 4 (grey/white), in the connector and fit the seal back in the connector.

10. Plug in the connector.


11. Secure the three cables with a cable tie.

12. Fit the fuel pump cover, return the rear seat cushions to their places and fold back the carpeting.