Tip: Malfunctions in the operation of the fuel gauge sensor are most often associated with wear on the contact part of its rheostat. This can be verified by measuring its electrical resistance with an ohmmeter while smoothly moving the lever with the float from one extreme position to another. The defective sensor must be replaced.
Removing
1. Remove the fuel module (see "Engine fuel module 11183 (1,6i) - removal and installation").
2. The fuel module cover is held on two rails. A spring is put on one of the guides. The spring is fixed with a retaining ring installed in the upper annular groove of the guide. To remove the fuel gauge sensor with a slotted screwdriver with a narrow blade, pry off and slide the retaining ring into the lower groove of the guide.
3. Raise the cover of the fuel module.
4. Remove the wire tip from the output of the fuel pressure regulator.
5. We press the clamp of the wire block...
... and disconnect the block from the fuel module cover.
6. Use a slotted screwdriver to release the wire block retainer.
7. Disconnect the block from the fuel pump.
8. We release two clamps of the fuel level sensor.
9. We shift the sensor along the grooves of the fuel module housing and remove it.
Installation
Install the new fuel gauge sensor in reverse order.