Appendix K. Measuring Part Strengthening for LLS Fuel Level Sensors
IMPORTANT! Strengthening the measuring part of the LLS fuel level sensors is only allowed for removable filler caps.
Option 1. Strengthening the measuring part of LLS fuel level sensors using steel pins and collars.
Materials used:
- 3 x М6 Ø16 female steel collars
- 3 x М6 Ø20 female steel collars
- DIN 975 М16 threaded pin – 3×2…3 m (depending on the size of the installed LLS fuel level sensor)
- DIN 975 М6 threaded pin (1 m)
- 6 x DIN 934 М16 nuts
- 6 x DIN 125 Ø17 flat washers
- 6 x DIN 127 Ø16.2 grovers (spring washers)
- Automobile sealant
It is forbidden to use plumbing collars with rubber seals that are not intended for use in aggressive environments.
Installation procedure: 1. Remove the filler cap. 2. Do 3.2, 3.4, 3.5, 3.6 with due regard to the recommended LLS fuel level sensor installation place on the filler cap (Figure 44).
3. Drill holes for the DIN 975 threaded pins as illustrated in Figure (Figure 45). The dimensions provided are for reference only and depend on the specific design of the filler cap.
All types of work associated with making holes, cutting, welding, and soldering should be performed in a well-ventilated area, at a safe distance from combustibles and lubricants.
4. Cut the threaded pins to the desired length. Threaded pin length must be 20-40 mm shorter than the length of the LLS fuel level sensor.
5. Install and secure the LLS fuel level sensor on the filler cap, according to the Section. 4.1
6. Install three threaded pins as illustrated in Figure (Figure 46).
7. Determine the length (L1) of the DIN 975 M6 threaded pin, as illustrated in Figure (Figure 47).
- Attach the threaded part of the Ø16 collar to the Ø16 threaded pin.
- Attach the threaded part of the Ø20 collar to the measuring part of the LLS fuel level sensor.
- Determine the L1 length, by inserting any Ø3…4 stud into the threaded holes of the clamps, and comparing the dimensions (linear and angular) indicated in fig. (Figure 47)
8. Cut the DIN 975 M6 threaded pins to the length L1.
9. Assemble steel collars as illustrated in Figure (Figure 48).
10. Fit the filler cap on the vehicle's fuel tank, with the LLS fuel level sensor and the reinforced structure installed.
Option 2. Strengthening the measuring part of LLS fuel level sensors with steel rods.
Materials used:
- Steel rods GOST 5781-82; GOST 10884-94 Recommended diameters of the rods: 12; 14; 16 mm. – 3х2…3 m.
- Steel pipe GOST 8731-78; GOST 3262-75 Recommended pipe diameter (external diameter x wall thickness): 28х2.5; 30×3; 32х4 mm. – 300 mm.
Installation procedure:
1. Remove the filler cap.
2. Do 3.2, 3.4, 3.5. 3.6
3. Install and secure the LLS fuel level sensor on the filler cap, according to the Section. 4.1
4. Perform welding works as illustrated in Figures (Figure 50, Figure 51), following angle dimensions illustrated in Figure (Figure 49).
All types of work associated with making holes, cutting, welding, and soldering should be performed in a well-ventilated area, at a safe distance from combustibles and lubricants.
5. Fit the filler cap on the vehicle's fuel tank, with the LLS fuel level sensor and the reinforced structure installed.
Option 3. Strengthening the measuring probe of LLS fuel level sensors with a flange.
See Appendix M.
