Fuel Level Sensor -G-, REMOVING AND INSTALLING: Removing

WARNING: This page is about a different variant/trim than selected.

Follow all safety precautions, refer to WORKING ON FUEL SYSTEM .

Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .

The fuel tank must be completely empty to remove the fuel level sensor -G-. Procedure to empty the fuel tank, refer to FUEL TANK, DRAINING .

-- Remove the right rear single seat in the second row of seats, refer to Seat Frames .

WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

Fig 1: Cut The Floor Covering Along The Perforation

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-- Fold carpet cut-out to side in direction of -arrow-.

Fig 2: Identifying Locking Flange Cover - Tightening Specifications

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-- Remove nuts -1 to 4- and remove right locking flange cover.

-- Disconnect the connector -4- on the right locking flange.

Fig 3: Fuel Lines Components Location

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-- If equipped, disconnect the connector -3- on the locking flange.

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Vehicles with parking heater: Disconnect the fuel line to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

Fig 4: Identifying Removal Of Locking Ring With T10202

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Version 1

Fig 5: Identifying Electrical Connectors -1 - And -2- On Underside Of Right Locking Flange

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-- Pull right locking flange with seal out of fuel tank a bit.

-- Disconnect electrical connectors -1 and 2 - on underside of the right locking flange.

-- Disconnect fuel lines -2 and 3-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 6: Fuel Delivery Unit Components Location

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-- Reach into the opening in the fuel tank, press the releases -arrow- and disconnect the auxiliary heater supply line -1- from the fuel delivery unit.

-- Remove the right locking flange and seal.

Version 2

Fig 7: Fuel Tank Components Location

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-- Pull the locking flange -4- out of the fuel tank slightly and remove the seal -1-.

-- Disconnect the connectors -2 and 3- on the bottom of the locking flange.

-- Remove the fuel line -5- from the fuel tank and disconnect it. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Lay the locking flange with the fuel lines still connected to the side.

Continuation for All Vehicles

Fig 8: Identifying Removal Of Fuel Level Sensor Through Guide -Arrow 2- While Pressing Locking Tab -Arrow 1-

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-- Reach into the fuel tank opening and remove the Fuel Level Sensor -G- from the guide -arrow 2- while pressing locking tab -arrow 1-.

NOTE:

The Fuel Level Sensor -- is shown without the fuel tank to provide a better illustration.