16 12 000 Removing and Installing/Replacing Fuel Gauge Sensor (Right)

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Special tools required:

16 1 020

IMPORTANT:

Ensure adequate ventilation in the place of work!

Ensure absolute cleanliness when working on the open fuel tank.

Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown!

Necessary preliminary tasks:

Draw off fuel from fuel tank See 16 00 005 DRAINING AND FILLING FUEL TANK
Remove rear seat See 52 24 005 REMOVING AND INSTALLING/REPLACING REAR SEAT (NORMAL) and 52 25 010 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR SEAT

Fold floor trim panel (1) (carpet) forwards.

Detach insulating mat (2) at perforation and fold back towards rear. Pop out rubber plugs here.

Fold back rubber mat.

Fig 1: Detaching Insulating Mat At Perforation

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IMPORTANT: Do not damage gasket.

Release screws (1) and fold back metal cover.

Fig 2: Releasing Screws & Folding Metal Cover

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IMPORTANT: Fuel hoses are pressurized.

Unfasten plug connection (1) and disconnect.

Unfasten hoses and detach carefully.

Do not damage connecting piece when doing so.

Fig 3: Identifying Plug Connection

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Release screw cap with special tool 16 1 020 and remove. See 16 1 020 PIN WRENCH

Installation:

Replace seal.

Tightening torque 16 14 2AZ See 16 14 FUEL PUMP

Fig 4: Identifying Special Tool (16 1 020)

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IMPORTANT:

Risk of breakage!

Carefully raise service cap. In so doing, do not pull excessively on connecting piece of fuel feed.

Installation:

Service cap can only be installed in one position.

When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.

During torque tightening, notch (3) on screw cap can be clearly heard and felt to engage toothed segment (4) on fuel tank.

Replace seal.

Fig 5: Identifying Lug, Notch On Screw Cap & Toothed Segment

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IMPORTANT: Do not bend sensor.

Disconnect plug connection (2).

Disengage fuel level sensor (1) and carefully feed out of tank opening.

Fig 6: Identifying Plug Connection & Fuel Level Sensor

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NOTE: Fuel level sensor for fuel gauge on right with plug connections.

Fig 7: Identifying Fuel Level Sensor With Plug Connections

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NOTE:

Only when changing fuel pump: Carefully remove cap with spiral hose and fuel pump from fuel tank.

Fig 8: Identifying Cap With Spiral Hose & Fuel Pump

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