Fuel Supply Sensor 3 -G237- (Tubular Sender - Right Side), Removing and Installing

Fuel Supply Sensor 3 -G237- (tubular sender - right side), removing and installing

Removing
Observe safety precautions.
Observe rules for cleanliness.

^ The right side fuel tank chamber must not be more than 1/3 full when removing tubular sender. Draining fuel tank.

CAUTION: Note additional steps required when disconnecting battery

- With ignition switched off disconnect battery Ground (GND) strap.
- Open fuel filler cap briefly, then close it again.
- Remove floor lining in luggage compartment.





- Detach cover for flange -arrows- (right side).





- Carefully detach connectors -1- and -2- at flange (right side).

WARNING: Fuel system is under pressure. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.





- Mark fuel supply pipe -1- and fuel return pipe -3- and disconnect (press release tabs).

Vehicles with auxiliary heater
- In addition, disconnect supply pipe for auxiliary heater -2-.





All models
- Unscrew bolts (arrows) and remove retaining ring for flange (right side).
- Remove flange and take off O-ring.





- Unplug connectors -1 to 3- on underside of flange (right side).

Notes:
^ To separate the pipe connections described in the following sections, pull the fuel pipes to the opening in the fuel tank.
^ In the following illustrations, some of the components are shown as they appear removed from the vehicle.





Vehicles with auxiliary heater
- Pull out suction pipe -1- for auxiliary heater from brackets on tubular sender (arrows).





All models
- Through opening on right side of fuel tank, detach fuel pipes -1- and -2- leading to fuel delivery unit (left side) by pressing the release tabs. 3- Fuel delivery unit (right side) with Transfer Fuel Pump (FP) -G23-





- Through the right side opening of fuel tank, press release tabs (arrows) and detach supply pipe -1- and Fuel Supply Sensor 3 -G237- -Item 2-.
- Swing Fuel Supply Sensor 3 -G237- to right side.





- Press down both retaining clasps on mounting sleeve for fuel delivery unit (arrows).
- Pull up fuel delivery unit slightly and at the same time pull out Fuel Supply Sensor 3 -G237-.

Installing





- Before installing fuel delivery unit, pull both retaining clasps on the mounting sleeve upwards until they lock (arrows).
- Then carefully press fuel delivery unit into mounting sleeve until it audibly engages.





- Press on supply pipe -1- and Fuel Supply Sensor 3 -G237- (-Item 2-) until they audibly engage.





- Through the right side opening in fuel tank, attach supply pipes -1- and -2- leading to fuel delivery unit (left side) until they audibly engage. 3- Fuel delivery unit (right side) with Transfer Fuel Pump (FP) -G23





Vehicles with auxiliary heater
- Insert suction pipe -1- for auxiliary heater into brackets (arrows) on tubular sender.





All models
- Plug in electrical connectors -1 to 3- on underside of flange (right side).

- Insert flange (right side) with new O-ring. Installing position:





^ The connectors are perpendicular to the direction of travel.
^ Distance x (left) = distance x (right)





- Tighten retaining ring for flange (right side) in diagonal sequence (arrows).





- Press on fuel supply pipe -1- and fuel return pipe -3- until they audibly engage.

Vehicles with auxiliary heater
- In addition, press on fuel supply pipe -2- for auxiliary heater until it audibly engages.





All models
- Attach electrical connectors -1- and -2- to flange (right side).





- Tighten cover for flange (right side) -arrows-.
- Connect battery. Note additional steps required after reconnecting battery.





Tightening torque