Fuel Gauge Sender: Service and Repair

- Fold down RH rear seat backrest.
- Remove panels and cover and trunk mat.
- Remove RH wheelhouse panel. Models with soft panel: turn corner of panel up.
- Unscrew the two covers over the fuel level sensor and fuel pump.





- Undo the fuel level sensor connector and take leads apart.
- Check sensor, see Specifications.

Wrench 999 5486:

- Unscrew plastic nut from fuel level sensor. Use tool 999-5486. Only remove the nut.
- Lift up fuel level sensor. Feed lead through at same time.
- Remove seal.

TIP: Put nut back on tank sleeve, otherwise pipe stub swell and nut will be difficult to install later.

- Check fuel level sensor function. See Fault Tracing Procedures for appropriate Instrument panel. Testing and Inspection
- Assemble in reverse order. Fit new rubber seal. Grease top and inside with a little Vaseline.
- Turn fuel level sensor so sensor lead is to the left.
- Tighten nut.





Fuel level sensor fits in center of body panel.
If fuel level sensor nut is not centered relative to the hole in the body panel, undo and center the fuel tank.





- Hoist car up.
- Undo tank belt and push tank forward with hands as far as it will go.
- Lower car.





- If fuel tank needs further adjustment, this can be done with a hammer shaft used as a lever between the fuel pump fitting nut and body panel. Bend carefully so as not to damage nut or panel.
- Undo nut and remove level sensor as per Fuel level sensor replacement procedure above.





- Tighten tank belt once work on level sensor is complete.
- Hoist car up.
- Push lank forward to center level sensor nut in hole in body panel.
- Tighten tank.
- Lower car.
- Reassemble as per sensor replacement procedure above.