Fuel level sensor — removal and installation (Defender 2007+)

Special tool(s)

Fuel tank spanner 310-118

Removal

Warnings:

• After completing repairs, inspect the fuel system for leaks. Failure to do so could result in injury.
• Do not carry or use a cell phone while working with or in the immediate vicinity of any fuel related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• If fuel gets into your eyes, rinse them with cold water or a special eye wash solution and seek medical attention immediately.
• This procedure involves handling fuel. Always be prepared for possible fuel splashing and use caution when handling fuel. Failure to follow these instructions may result in injury.
• Wash your hands thoroughly after handling fuel, as prolonged contact with the skin may cause irritation. If irritation occurs, seek medical attention.

Warnings:

• Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. Therefore, absolute cleanliness is required when working with these components.
• Be sure to plug all open ports and lines. Failure to do so may result in dirt entering the fuel injection system.
• Keep the area of the service station where the vehicle is being worked on as clean and dust-free as possible. Dirt and dust from clutch, brake, machining, or welding work can contaminate the fuel system and cause problems later.

1.

WARNING: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.

Raise and support the vehicle.

2. Disconnect the ground wire from the battery.

For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).

3. Remove the fuel tank.

For more information, refer to the chapter: Fuel Tank (310-01 Fuel tank and fuel lines - Diesel engine ID4 2.4L, Removal and installation).

4. Remove the fuel level sensor.

• Using a special tool, remove the retaining ring.
• Remove the seal and dispose of it.

Installation

1.

NOTE: Clean the contact surfaces of the parts.

Install the fuel level sensor.

• Install a new seal.
• Using the special tool, tighten the retaining ring to a torque of 35 Nm.

2. Install the fuel tank.



For more information, refer to the chapter: Fuel Tank (310-01 Fuel tank and fuel lines - Diesel engine ID4 2.4L, Removal and installation).

3. Connect the ground wire to the battery.

For more information, refer to the chapter: Connecting the Battery (414-01 Battery, Battery Mounting and Cables, General Procedures).