Necessary preliminary tasks

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Release screws (1) and remove cover (2) from left side of fuel tank.

Fig 1: Identifying Fuel Tank Cover With Mounting Screws

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Disconnect plug connection (1).

Press grey ring (2) towards sensor unit and pull out fuel feed line (3) straight.

IMPORTANT: Do not use any tools to release the fuel feed line.
After installing fuel feed line, carry out tensile test and leak test.

Fig 2: Disconnecting Plug Connection

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Release screw cap with special tool 16 1 020 and remove service cap.

Installation:

Procedure for tightening screw cap, see next work step.

Fig 3: Releasing Screw Cap Using Special Tool (16 1 020)

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IMPORTANT: Fit screw cap without using a tool and tighten hand-tight.
Then tighten screw cap with special tool 16 1 020 until notch (1) points to marking (2).

NOTE: Illustration shows the tank removed.

Fig 4: Tightening Screw Cap Using Special Tool (16 1 020)

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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.

Make sure that the lever sensor moves freely before fitting the service cap.

Clean sealing faces and install new seal.

Fig 5: Identifying Service Cap Lug And Opening On Fuel Tank

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Attach an auxiliary lead (1) to hose pack (2) through service opening.

The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.

Installation:

Make sure when pulling through the hose pack that the tank ventilation system in the tank tunnel is not damaged.

Fig 6: Identifying Auxiliary Lead And Hose Pack

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Carefully lift sensor unit (1) out of tank.

In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.

NOTE: Illustration shows the tank removed.

Fig 7: Lifting Sensor Unit

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Remove sensor unit (1) and hose pack (2) with auxiliary cable to left.

Installation:

When replacing the sensor unit, modify the end of the auxiliary lead to the new hose pack and carefully pull in through the tank.

NOTE: Illustration shows the tank removed.

Fig 8: Removing Sensor Unit And Hose Pack With Auxiliary Cable

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