Replacement of switches and sensors GAZelle Next

Replacement of sensors and switches GAZelle NEXT

In this article we consider the replacement of the oil pressure emergency warning lamp sensor, the replacement of the parking brake warning lamp switch, the replacement of the brake light switch, the replacement of the reverse light switch and the replacement of the fuel level gauge sensor.

In previous articles we have considered how to replace the instrument panel switches (article — Replacement of the instrument panel switches and horn) and the article — replacement of the engine management system sensors (article — Replacement of the Cummins ISF2.8 engine management system sensors).

Replacement of the emergency pressure drop sensor

**Fig. 1.** Oil pressure emergency drop sensor.

The sensor is screwed into the oil gallery of the front cover of the cylinder block above the oil filter.

We disconnect the negative battery terminal.

**Fig. 2.** Prising up the wiring connector plate.

We prise up with a screwdriver and slide the wiring connector plate.

**Fig. 3.** Disconnection of the wiring connector from the sensor.

We disconnect the wiring connector from the sensor by pressing the retainer.

We slacken the sensor.

**Fig. 5.** Unscrewing of the sensor from the oil gallery.

We unscrew it from the oil gallery.

Important: we install the new sensor in the reverse order.

Replacement of the parking brake switch

Tools required: 11 mm spanner, cross-head screwdriver.

**Fig. 6.** Raising of the parking brake lever.

We raise the parking brake lever so that the stop moves away from the switch.

**Fig. 7.** Unscrewing of the cover securing screw.

We unscrew the screw securing the cover of the lever mechanism.

**Fig. 8.** Removal of the cover of the lever mechanism.

We remove the cover. We disconnect the wiring connector from the terminal.

**Fig. 9.** Unscrewing of the switch from the bracket.

We unscrew the switch from the bracket on the parking brake actuating lever.

Important: we install the switch in the reverse order.

Replacement of the brake light switch

We check the brake light switch installed on the brake pedal bracket. We press the brake pedal fully.

With the switch plunger fully extended, the brake lights must be on, and when the plunger is pressed in by 4–5 mm (press with a finger) they must go out.

Otherwise, we replace the switch.

**Fig. 11.** Unscrewing of the lower switch securing nut.

We unscrew the lower switch securing nut.

**Fig. 12.** Removal of the brake light switch.

We remove the switch.

**Fig. 13.** Disconnection of the wiring connector from the switch.

We squeeze the retainer and disconnect the wiring connector from the switch.

**Fig. 14.** Installation of the brake light switch.

We install the switch in the reverse order.

Important: we adjust the position of the switch using two nuts so that, when the brake pedal is pressed, the brake lights come on, and when the pedal is released they go out.

Replacement of the reverse light switch

**Fig. 15.** Location of the reverse light switch.

The reverse light switch is screwed into the gearbox housing on the left-hand side.

We press the retainer and disconnect the wiring connector from the switch.

**Fig. 17.** Slackening of the switch with a 22 mm spanner.

We slacken the switch with a 22 mm spanner.

**Fig. 18.** Unscrewing of the switch from the gearbox housing.

We unscrew the switch from the gearbox housing.

To test the sensor we connect a 12 V lamp and apply a voltage of 12 volts.

**Fig. 19.** Testing of the reverse light switch.

The lamp must come on when the ball of the switch is pressed with a finger, and the ball travel must be 1–2 mm.

**Fig. 20.** Installation of the switch with sealing ring.

Important: we install the switch in the reverse order, refitting the sealing ring.

Replacement of the fuel level sensor

The fuel level gauge sensor is part of the fuel pick-up unit located in the fuel tank.

The sensor must be replaced if the fuel level gauge in the instrument cluster changes its readings chaotically for no apparent reason.

We disconnect the negative battery terminal.

**Fig. 21.** Removal of the fuel pick-up unit.

We remove the fuel pick-up unit (article — Repair of the fuel pick-up unit).

**Fig. 22.** Disconnection of the fuel level sensor wiring connector.

We squeeze the retainer of the fuel level sensor wiring connector.

**Fig. 23.** Disconnection of the connector from the socket.

We disconnect the connector from the socket.

**Fig. 24.** Squeezing of the retainers and removal of the sensor.

We squeeze the two retainers. We slide along the guide and remove the sensor.

Important: we install the fuel level sensor in the reverse order.