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Fuel level sensor/fuel pump, Z19

Fuel level sensor/fuel pump, Z19

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


1. Remove Fuel tank .

2. Detach the ground lead from the retaining bolt.

Important

The connector must not be removed from the lid of the fuel container.


3. Unplug the following connectors:

3.a. Water level switch, fuel filter (692)


3.b. Fuel temperature sensor (651).

3.c. Fuel filter heating element (410)

3.d. Cars with auxiliary heater : Fuel pump connector.

4. Cut the cable tie holding the cables to the fuel line.

5. Certain cars: Remove the retaining clip.

All cars: Mark the delivery and return lines before removal. Carefully detach the fuel lines from the fuel reservoir (move the catches aside with a screwdriver). The pressure side is marked "Pressure" and the return side is marked "Return" on the fuel reservoir. In addition, detach the heater feed line.


6. Remove the screw ring using the 83 94 462 Fuel pump tool .


7. Raise the fuel reservoir (including fuel level sensor) until its upper section is about 50 mm above the fuel tank. Then turn the reservoir clockwise about 80° and carefully remove the reservoir.


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


To fit

Note

Spray the connectors with Contact Protect anti-corrosion agent or the like before connection.



1. Clean sealing surfaces.

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


3. Carefully lower the fuel reservoir (including fuel level sensor) into position. It may be necessary to lift the fuel level sensor's lever slightly to get the reservoir into position. Check that the index markings on the tank and fuel reservoir align. 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. Attach the screw ring with the 83 94 462 Fuel pump tool .

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. Make sure that the catches have snapped in place over the connections.


8. Attach any heater feed line.

9. Certain cars: Fit the retaining clip manually to prevent damage to the thread. Check that the retaining clip does not press against the yellow hooks.

Tightening torque: 2 Nm (1.5 lbf ft)

Important

Use the original bolt as it is designed especially for the purpose.


10. Attach the ground lead to the retaining bolt.


11. Plug in the following connectors:

11.a. Water level switch, fuel filter (692)

11.b. Fuel temperature sensor (651)

11.c. Fuel filter heating element (410)

11.d. Cars with auxiliary heater : Fuel pump connector.

12. Secure the wiring harness to the fuel line with a cable tie.

13. Fit Fuel tank .