Remove/install fuel level sensor

AR47.10-P-7000PD

Remove/install fuel level sensor

26.7.06

1.3.04

"Disconnect/connect battery ground line" removed



Removing

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Pump out fuel

 If fuel tank is full, extract fuel, see:

Empty fuel tank, fill again.

AR47.10-P-4001PP

2.1

Fold rear seat cushion (1) forward

Model 203.0 with code (287a) Through-loading facility

Model 203.2/7

2.2

Remove rear seat cushion (1).

Model 203.0 without CODE (287a) through-loading feature

AR91.12-P-1020PC

Model 209.316

AR91.12-P-1020P

3.1

Remove floor covering (3)

Model 203.0 with code (287a) Through-loading facility

Model 203.2/7

4

Remove both end covers (4) at frame floor

5

Disconnect plug in electrical plug connection (5) on fuel level sensor, left half of tank (B4/1)

6

Disconnect fuel feed line (6) and fuel return flow line (7) at fuel gage sensor, left half of tank (B4/1)



*000589403700

7

Use pronged wrench to unscrew both ring nuts (8)



*203589010700

8

Remove locating cover (13) together with shaped seal (14)



Fuel gage sensor modified

BT47.10-P-0007-01A

9

Pull fuel level sensor, right half of tank (B4/2) out a little

10

Detach electrical plug connection (15) on fuel level sensor, right half of tank (B4/2)

11

Disconnect feed line (10) and suction jet pump swirl pot connecting line (11) at fuel gage sensor, right half of tank (B4/2)

 New fuel gage sensors, right half of tank (B4/2) are fitted with plugs to the feed line (10) and suction jet pump swirl pot connecting line (11).



Information on fuel gage sensor

AH47.10-P-7000-02A

12

Remove fuel gage sensor, right half of tank (B4/2)

13

Remove fuel gage sensor, left half of tank (B4/1)



Install

14

Fit molded sealing ring (12) onto fuel gage sensor, left half of tank (B4/1)

 Replace molded sealing (12) to avoid leakage.

 To avoid molded sealing ring (12) dropping into fuel tank.

15

Guide feed line (10), suction jet pump swirl pot connecting line (11) and electrical plug connector (15) through the fuel tank.

16

Remove molded sealing ring (12) once more from fuel gage sensor, left half of tank (B4/1) and fit molded sealing ring (12) to fuel tank

17

Fit fuel gage sensor, left half of tank (B4/1) to molded sealing ring (12) on fuel tank

Marking on fuel level sensor, left half of tank (B4/1), must be aligned with marking on fuel tank.

18

Plug together plugs (16) for feed line (10) and suction jet pump swirl pot connecting line (11)

 Ensure plug sockets (16) are properly connected, check for tension and compression.

19

Plug in electrical plug connection (15) on fuel level sensor, right half of tank (B4/2)

20

Insert fuel gage sensor, right half of tank B4/2

21

Fit on molded sealing ring (14) at fuel tank

 Replace molded sealing (14) to avoid leakage.

22

Insert locating cover (13) in sectional sealing ring (14) to fuel tank

Marking on locating cover (13) must be aligned with marking on fuel tank.

23

Use pronged wrench to turn down ring nuts (8)



*BA47.10-P-1003-01E



*203589010700

24

Connect fuel feed line (6) and fuel return flow line (7) at fuel gage sensor, left half of tank (B4/1)

 Inspect hose clamps, fuel feed line (6) and fuel return flow line (7), replace if necessary.

25

Plug in electrical plug connection (5) on fuel level sensor, left half of tank (B4/1)

26

Refill fuel tank with fuel

 Check whether fuel tank is leaktight at the sectional sealing rings (12, 14).

AR47.10-P-4001PP

27

Install end cover (4) at frame floor

 Replace sealing profile if damaged.

28.1

Install floor covering (3)

For model 203.0 with code (287a) Through-loading facility

for model 203.2/7

29.1

Install rear seat cushion (1)

For model 203.0 without code (287a) Through-loading facility

AR91.12-P-1020PC

in case of model 209.316

AR91.12-P-1020P

29.2

Fold rear seat cushion (1) back

For model 203.0 with code (287a) Through-loading facility

for model 203.2/7

30

Connect STAR DIAGNOSIS, read out and erase fault memory



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

*WH58.30-Z-1048-13A

Number

Designation

Model
203, 209 without code 494/835

Model
203, 209 with code 494/835

BA47.10-P-1003-01E

Ring nut to fuel tank

Nm

85

–

Number

Designation

WH58.30-Z-1048-13A

STAR DIAGNOSIS diagnosis system, Compact Passenger Car

6511 1801 00