Table of contents: Removal ↓ Installation ↓
Attention! See safety precautions subsection 6.3.1 before starting work.
Removal
1. Disconnect the negative battery cable.
2. To access the sensor, remove the rear seat.
3. Loosen the mounting screws and lift the cover to access the sensor.
4. Disconnect the connection connector from the fuel level sensor and stick the connection connector to the car body using adhesive tape to prevent it from falling behind the fuel tank.
5. Release the pressure from the fuel system (see subsection 6.3.1.7).
6. Mark the hoses to avoid confusion, then loosen the clamps on the fuel supply hose and the return hose.
7. Disconnect both hoses from the fuel level sensor and plug the open ends of the hoses.
8. Remember the position of the installation mark on the fuel level sensor (the arrow should point forward of the car). If there is no installation mark, apply it.
9. On models where the sensor is secured with a large ring, unscrew and remove it from the fuel tank. This is best done with a screwdriver inserted into the notch on the edge of the retaining ring. Gently tap the screwdriver until the retaining ring is loosened counterclockwise until it can be turned by hand.
10. On models where the sensor is secured with bolts, loosen and remove all mounting bolts and washers.
11. On all models, carefully remove the sensor from the top of the fuel tank, being careful not to bend the float arm or spill fuel on the seat upholstery or interior.
12. When removing the sensor, disconnect the fuel pump connection connector; reach into the fuel tank and squeeze the retaining clip to remove the fuel pump from the bottom of the fuel tank.
13. The fuel pump and fuel level sensor can then be removed together from the fuel tank.
14. Remove the rubber sealing ring and discard it; when installing, you must use a new one.
15. Loosen the mounting clamp, then disconnect the fuel pump hose from below the fuel level sensor and remove the sensor from the pump.
16. Wash the fuel filter in a high flash point solution.
17. Inspect the filter for signs of clogging or cracks and replace it if necessary.
Installation
1. Installation is carried out in the reverse order of removal.
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2. Please pay attention to the following points during installation.
3. Install the fuel level sensor onto the fuel pump, making sure the hoses are properly connected and securely fastened with clamps.
4. Install a new rubber sealing ring onto the fuel tank.
5. Make sure the fuel pump is securely fastened before installing the fuel level sensor.
6. If the sensor is secured with a retaining ring, align the mark on the sensor with the mark on the fuel tank and tighten the ring securely.
7. If the sensor is secured with bolts, align the marks on the sensor and fuel tank made prior to removal and tighten all mounting bolts securely.
8. Check that the fuel supply and return hoses are connected correctly and tighten the clamps securely.
9. Before installing the cover, connect the battery, then start the engine and check the fuel lines for any signs of fuel leakage.