Fuel Gauge Sender: Service and Repair

Fuel Level Sensor Replacement T19




- Remove battery negative lead.
- Remove draining hose on left side, 4-door.
- Fold forward seat back, 5-door.
- Remove carpet and covers in trunk
- Unplug connectors.
- Remove cover over tank gauge unit
- Clean area around unit and hose connections.
- Remove hoses from unit.
- Remove gauge unit and gasket.
- Remove clamps around filler pipe.





- Remove electrical connector. Press out rubber grommet.
- Withdraw lead to gauge unit.


NOTE: If tank is more than half full, fuel must be drained (Sheet metal tanks).





- Remove nut on gauge unit with special tool: P/N 999 54489.
- Lift out gauge.


- NOTE: Replace nut on tank neck or it may swell, causing nut to be difficult to refit and tank to leak.





- Replacing level sensor: first unhook the lower catch and then the upper catch.
- Unsolder leads.
- Fit new unit
- Reassemble in reverse order. See below



Assemble gauge unit




- Fit gasket In tank opening.
- Grease gauge until contact surface with a layer of vaseline (petroleum jelly).
- Lower unit carefully Into tank, taking care not to damage prepump mounts against splash guard In tank, See Illustration.

Align gauge unit




Line up arrows on sensor covering with seam on tank. Place sensor straight in tank. Turn sensor a few degrees counterclockwise, so that it will line up when the top nut is tightened. Tighten nut on tank gauge unit with special tool: P/N 999 5448-9

Torque: 35 Nm (25.8 ft lb)

- Locate lead in clip on side part under cover. Plug in connector.
- Fit hoses and check that they are securely attached to pipes on gauge unit.
- Screw cover back on.
- Fill tank.




- Always check tank for leaks.
If a leak is suspected, replace seal and nut.