Fuel level sender unit - removal and refitting

Caution: Refer to the precautions in Section 1 before proceeding. A new seal must be used when refitting the sender unit.

Saloon, Hatchback and Estate models
All models except 2.0 litre DOHC 1 Remove the fuel tank.

2 Unscrew the sender unit from the tank by engaging two crossed screwdrivers in the slots on either side of the sender unit mounting flange. Recover the seal. Check the condition of the gauze filter on the fuel pickup pipe, and renew it if there is any sign of deterioration.

3 Refitting is a reversal of removal, but fit a new seal.

2.0 litre DOHC models
4 On these models the sender unit is combined with the fuel pump. See Section 8 for unit removal and refitting.

P100 models
5 Remove the cargo area (Chapter 12).

6 Disconnect the wiring plug from the sender unit.

7 Identify the fuel hose locations, as an aid to refitting, then disconnect the hoses from the sender unit and plug them.

8 Proceed as described in paragraph 2.

9 Refitting is a reversal of removal, but fit a new seal, and ensure that the fuel hoses are correctly connected. If the hoses were originally secured with crimped type clips, discard these and use new worm drive clips.

Refit the cargo area.

Throttle pedal - removal and refitting

Removal
1 Disconnect the battery negative lead.

2 Remove the lower facia panel from the driver’s side.

3 Prise off the securing clip and disconnect the end of the throttle cable from the top of the pedal (see illustration).

11.3 Throttle pedal assembly - cable connection arrowed
11.3 Throttle pedal assembly - cable connection arrowed

4 Remove the two securing nuts, one accessible from the driver’s footwell, the other from the engine compartment, and withdraw the pedal and bracket assembly (see illustration).

11.4 Throttle pedal securing nut (arrowed) in engine compartment
11.4 Throttle pedal securing nut (arrowed) in engine compartment

Refitting
5 Refitting is a reversal of removal, but on completion check the throttle cable adjustment.

    See also:

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    Electrical fault finding - general information
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