Attention! See precautions subsection 6.3.1 before starting work.
Removing
1. Disconnect the negative battery cable.
2. To gain access to the sensor, remove the rear seat.
3. Loosen the fixing screws and lift the cover to gain access to the sensor.
4. Disconnect connector (s) connection from the fuel level sensor and stick the connection connector to the car body with adhesive tape so that it does not fall behind the fuel tank.
5. Release pressure from the fuel system (see subsection 6.3.1.7).
6. Mark the hoses so as not to confuse them, then loosen the fastening clamps of the fuel supply hose and the return hose.
7. Disconnect both hoses from the fuel level sensor and plug the open hose holes.
8. Remember the position of the setting mark on the fuel level sensor (the arrow should point ahead of the car). If there is no installation mark, apply it.
9. On models where the sensor is attached 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 rib of the retaining ring. Gently tapping on the screwdriver, unscrew the retaining ring counterclockwise until it can be rotated by hand.
10. On models where the sensor is bolted, unscrew 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 and 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 mounting clip to remove the fuel pump from the bottom of the fuel tank.
13. Then, the fuel pump and fuel level sensor can be removed from the fuel tank together.
14. Remove the rubber o-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 if necessary.
Installation
1. Installation is carried out in the reverse order of removal.
2. When installing, pay attention to the following points.
3. Install the fuel level sensor to the fuel pump, making sure the hoses are properly connected and secured with clamps.
4. Install a new rubber o-ring to the fuel tank.
5. Check that the fuel pump is secure 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 bolted, align the marks on the sensor and fuel tank made before removal and securely tighten all mounting bolts.
8. Check the correct connection of the fuel supply and return hoses and securely tighten the mounting clamps.
9. Before installing the shroud, connect the battery, then start the engine and check the fuel hoses for signs of fuel leakage.