Replacing (removing) the fuel pump and fuel level sensor

Russian car owners love the first domestic crossover VAZ 2121 Niva and continue to use it for 40 years. Over the years, the car has evolved a bit. True, its appearance has hardly changed, but the power plant has changed: the carburetor was replaced by an injector. In both types of car modifications, the owners are faced with difficult puzzles by the fuel level sensor (FLS). This has an uncomfortable effect on driving, since the driver is not sure of the exact amount of gasoline in the tank.

Next, we will talk about the causes and symptoms of FLS malfunction, what types of sensors exist, which one to choose, how to check, replace and adjust.

Principle of operation

On VAZ 21213–21214 models, 2 types of fuel level sensors were installed, but both of them were lever type. In the injection modification of the car, an electric pump was simply added to the previously existing mechanism. Therefore, the node is now called the EBN module. But at the same time, the basic design of the FLS has not changed. In both the first and second views of the sensor, the main elements remained, such as:

1. Resistor (potentiometer).
2. Movable contact (slider).
3. Metal lever.
4. Float.
5. Fuel intake.

How does the mechanism work? When filling the tank with gasoline, the fuel sensor float remains on the surface and rises with the level. The slider integrated into the metal lever also begins to move upward along the resistor. In this case, the resistance parameters decrease (at a maximum there should be 20 Ohms, and at a minimum 250 Ohms), so the voltage increases (Ohm's law U = IR). The higher voltage is sent through the wire to the level gauge in the instrument panel and shows more gasoline. This is how the driver monitors changes in the tank.

Pumps since 2005

After returning to the VAZ-21214 project, the catalogs already have slightly different numbers and it is already difficult to say how the original copies were designated. Starting with the introduction of ramp 214 on the VAZ-21214, Utesovsky EBN 21214-1139009-10 with 3M FLS began to be used. Here, tubes with nuts are also used on the lid, as in previous versions. Although often the number 21214-11390009 is still used on the cover without indicating the last digits, and the cleaning filters also do not look the same for everyone. In any case, now everything in the Utes nomenclature has returned to normal and corresponds to the VAZ nomenclature.

EBN 21214-1139009-10. According to the manufacturer, it has been used on VAZ-21214 cars with Euro-2 and Euro-3 since 2006.

Electric fuel pump 21214-1139009-10 produced by Utes

• Manufacturer: Utes;
• Date of withdrawal - 08.2009;
• Pump - Bosch 0 580 454 035;
• Housing - Utes, 21214-1139009-10, with nuts;
• FLS - Utes 3M (marking on resistor 3-01).

There are quite a few analogues of this pump - both SEPO and Pekar, and Utes also has analogues for it - the latter has the number 21214-1139009-10K, but is equipped with a pump from Joinhands Auto Spare Parts CO., LTD.

Causes and symptoms of malfunction

The FLS lever mechanism is constantly in an aggressive environment, that is, in gasoline. The fuel is not ideal and often contains water. Therefore, over time, the contacts oxidize and stop working properly. In addition, the moving mechanisms simply wear out, primarily this applies to the slider and resistor. Often the float becomes depressurized, causing it to partially fill with gasoline and begin to give incorrect data. Sometimes the cause of the malfunction is a disconnected (broken) wire in the instrument panel combination.

Main faults and solutions

The indicator arrow points to 0, regardless of the amount of gasoline in the fuel tank:

• Remove the FLS hatch (under the 2nd row of seats) and disconnect the pink wire. Turn on the ignition. If the needle rises, then the sensor “has died for a long time.” Needs replacement.

The arrow freezes at the maximum scale value (1) or more:

• Remove the instrument cluster. Disconnect the red wire from block No. 3 in the panel and turn on the ignition. If the arrow falls, then the FLS is faulty, and if not, then the problem is in the wiring. There may be a short circuit somewhere.

The fuel reserve indicator light is constantly on:

• Most likely the sensor wire has shorted to ground. Check the mechanism and eliminate the short circuit.

Sometimes the pointer arrow twitches and freezes in an arbitrary position. These signs indicate that the slider on the resistor is most likely jammed.

Types of sensors

Despite the classic external style that has been established for decades, the Niva has experienced some metamorphoses within itself. One of the most massive transformations can be considered the “tricks” with the fuel sensor that AvtoVAZ performed. If you open the catalog, even an experienced mechanic will be blindsided by the variety. We figured it out, organized everything and compiled a nomenclature according to the chronology of the FLS release.

Table 1. Original numbers of fuel level sensors

Comment from a thematic forum: “VAZ has made an incredible number of modifications to these sensors, so it’s difficult to find the one you need. At least 3 of my friends who carried out this replacement due to wear on the resistor were unable to find the same one. I had to put what was there. At the same time, the pointer arrow moves. But you can adapt.”

Price

You can buy FLS for VAZ 21213-21214 in many spare parts stores. But service workshop professionals recommend contacting specialized LADA retail outlets, or even better, Niva mono-brand stores. Here managers are more competent and understand the problems of customers. If the fuel sensor recommended by the manufacturer is not available, then ordering via the Internet is suitable.

Table 2. Cost of FLS for VAZ 21213–21214

Sources: old.autopiter.ru, ada-original.ru

Before replacing, it is recommended to look at the original sensor number in order to buy exactly the one that should be installed. Although they can be interchanged, the manufacturer still does not recommend using another part. Otherwise, the arrow may “lie,” as a forum participant wrote above.

A little about injection

Perhaps many of you know about all the vicissitudes of the development of a fuel injection system for Niva, perhaps not, it is likely that some of you know and even more than we do. So we don’t want to mislead and we will try to briefly retell the words of the participants in the development process described in the book “A Flame of High Thought.”

Work to find ways to introduce injection at AvtoVAZ, according to the assurances of the designers, has been carried out since the 70s. But it was only towards the end of the 80s that significant changes began. AvtoVAZ is looking for partners among three global manufacturers: GM, Bosch, Siemens. Well, as we all know, GM chooses in June 1990.

The first deliveries of ECM components were made in 1993 and included kits meeting Euro-1 toxicity standards for the Niva. By the way, by the time deliveries began, some of the system’s components had been adapted for production at the facilities of the domestic defense industry. The fuel pumps themselves were supplied by overseas comrades. The decision to develop analogues for the GM system in Russia was announced back in 1992. At the beginning of 1993, the search for partners began.

The competition among potential Russian partners of Bosch was held for a year and a half from July 1993. It was won by JSC SEPO. The shares of the participants in the Bosch-SEPO JV are distributed as follows: Bosch - 60%, JSC SEPO - 20%, JSC Avangard (Engels) - 10%, JSC AvtoVAZ - 5%. (Newspaper “Kommersant” No. 195 dated 10/20/1995, p. 9).

Of course, Bosch competed with GM represented by Delphi for the right to localize production, but was able to offer more interesting conditions. Bosch chose the Saratov plant as a partner and they were supposed to organize production on its basis, but... the Germans did not like the building owned by SEPO and transferred to the joint venture, better known as Bosch-Saratov. Due to the fact that the premises were not ready, everyone in a friendly company left for the city of Engels to use the capacity of the local glow plug plant. The production of oxygen sensors, air flow sensors and M1.5.4 controllers was organized here. Equipment for the production of injectors had already been delivered, but calculations showed that there was absolutely no benefit in localizing the production of these components; as a result, this line was abandoned and the equipment was partially transferred to the production of electric fuel pump modules, which was not previously planned here.

Why all this backstory? Moreover, we cannot give a truthful answer as to who actually made the body (module) 21214-1139009-01 (were it SEPO themselves or Ulyanovsky Utes had already gotten involved, or, which looks unlikely, GM), and definitely not Let's tell you what kind of FLS there is (it very much resembles the shape of a product from SEPO, but that's just a guess). You never know if you have more complete information, we will be glad if you share it.

From what was found on the Internet, there is a description made by a forum participant about Nivas: “Pumps come in two types - with the marking on the flange “UTES” and an embossed catalog number starting with the numbers 21214, as well as older ones, in which the flange is not silver-tin , and bronze tint, there is no external marking, except for an arrow indicating the direction of installation. The connectors on the flange are also different - the Utes has an oval, horizontally oriented four-pin white connector, into which a “tail” 10-12 centimeters long with a square four-pole connector (pink, purple, gray and black wires) is inserted. The unnamed product (note that it is at least a third more expensive - most likely, it traces its ancestry back to GM systems) - has a tightly sealed dirty yellow chip on the flange, from which comes the same “tail” 10-12 cm long with a four-pin connector described above. That is, in terms of seats and connections, the EBNs are identical - they differ only in the width of the fuel intake (the “Utes” is wider, and this is better - there is less chance of blocking with stuck dirt). The fuel level sensors and the contacts for turning on the emergency fuel reserve lamp are identical, the floats are the same, they differ only in the color of the plastic.”

True, on the Internet we also found a version with a “bronze tint” without a white connector, but with the same yellow chip and engraved “Cliff” and “21214-1139009” on the cover, but what can you want from the Russian spare parts market.

This image is consistent with the description above.

As for EBN 21214-1139009-00, information about it appears between 06.2000. and 09.2001 According to all our data, these two pumps are interchangeable.

As for the first Niva with distributed injection (VAZ-21214-20-010) - ECM Bosch MP7.0, controller 2123-1411020-10 and 23 ramp - the spare parts numbers of which we can look at in the 1999 catalog (in addition to it), and which you can still trust, it says that the EBN used is the same as on the single-injection one - 21214-1139009-01.

EBN 21214-1139009-01. The first pumps used in the VAZ-21214 and developed in the era of collaboration with GM.

• Manufacturer - ;
• Date of withdrawal - ;
• Pump - GM;
• Housing - 21214-1139009;
• DUT - rectangular.

Description and photo are just above.

EBN 21214-1139009-00. EBN with Utesovsky building and Boshevsky pump.

• Manufacturer: Utes;
• Date of withdrawal - ;
• Pump - Bosch;
• Body - Utes 21214-1139009, metal cap, one-piece tube;
• DUT - rectangular.

Image from some brochure released after 2006. By the way, there is also a rectangular sensor.

How to check

The spare parts market is full of counterfeit and poor quality parts. Independent experts from auto publications recommend checking a new fuel level sensor before installation. To do this you will need a multimeter (tester). It will need to be switched to an ohmmeter.

On top of the DUM roof there are 2 electrical outlets. Plugs are inserted into them: one for the level, the other for the signal light. Install the positive probe of the tester to the level output, and the negative probe to ground. Next, move the sensor lever, simulating a full tank or an empty tank. The parameters on the tester should vary, from 20 (upper position) to 250 Ohms (lower). No jumps or drops are allowed. If there are defects, then a low-quality part has been identified. It must be returned to the store.

Replacement

To remove the old fuel level sensor and install a new one in the tank, you will have to remove many parts of the rear compartment. You will need tools: Phillips and flathead screwdrivers, 7 mm, 10 mm wrenches, pliers (2 pcs), a marker and a rag. It is advisable to carry out repairs outdoors or in a spacious room so as not to be poisoned by gasoline fumes. It is also recommended to buy a gasket for the FLS (45–50 rubles), since the old one often cannot be reinstalled. The replacement process itself looks like this:

1. Set the car to the handbrake.
2. Remove the negative terminal from the battery.
3. Unscrew 2 screws of the mat on each side.
4. Remove the clips from the side trims and the trims themselves.
5. Remove the 4 bolts from the 2 brackets for the rear row of seats.
6. Fold the backrest and remove the seat from the interior.
7. Pull back the fuel tank mat.
8. Unscrew the 2 screws securing the FLS hatch.

9. Mark one chip with a marker so as not to mix it up later.
10. Remove the 2 plugs (gasoline level and warning light).
11. Using a Phillips screwdriver, loosen the 2 fuel line clamps.
12. Unscrew the 7 nuts of the sensor cover (7 mm wrench).
13. Carefully remove the FLS from the tank.
14. Wait until the fuel drains from the filter (mesh).

15. Remove the gasket (be careful not to let parts fall into the tank).
16. Clean the seat.
17. Install a new fuel level sensor, but do not close the hatch.
18. Turn on the ignition and check the operation of the FLS on the dashboard.
19. Collect everything in reverse chronology.

On the injection Niva, the removal and installation of the EBN module takes place in the same sequence. Just to disconnect 2 hose fittings you will need 2 17 mm wrenches. And before removing the fuel lines, it is necessary to relieve the gasoline pressure in the rail.

Why does the FLS display the gasoline level incorrectly?

Sometimes the fuel quantity indicator arrow misleads the driver. This is usually caused by wiring problems or a faulty sensor. Incorrect readings occur for the following reasons:

• The on-board voltage is very different from the nominal voltage.
• The connection contacts of the indicator on the instrument panel or potentiometer have oxidized.
• The parameters of the FLS resistor do not correspond to the nominal value.
• The contacts of the potentiometer or slider are worn out.

Advice: if a serviceable sensor, after being removed and installed in the gas tank, begins to show the level incorrectly, you should remove it again and check the shape and stroke of the lever.

How to adjust

If you were unable to find the original sensor and had to buy an analogue, then the new resistor after replacement will lie, since it does not fit the parameters a little. This deficiency can be corrected. This is exactly why you will need pliers (2 pcs.). The order is as follows:

1. Fill the fuel tank full.
2. Turn on the ignition and remember the arrow readings (you can draw it on paper).
3. Remove the negative terminal from the battery.
4. Dismantle the FLS and slightly bend the lever with pliers (hold it firmly at the base with just one pliers).
5. Then install the sensor in the tank, connect the battery and turn the ignition switch.

Your task is to ensure that the arrow coincides exactly with the unit scale (1). The operation must be repeated until the result is achieved. This usually takes 2-3 approaches.

Interchangeability of electric fuel pumps

For those who did not want to read everything above, but quickly grasp the whole meaning.

21214 single injection. Use only your 01. Despite the direct indication in the catalogs that 00 can be used as a replacement for 01 - when talking about analogues and not about the original, it is better not to try.

21214 until 08.2009. 10 and their analogues. As for the first modifications of cars with distributed injection 21214-20-010 - take a look at what’s there before you buy. Most likely they cost 00 or 01. In most cases, we sell -10 for owners of cars before 2006, i.e. instead of 00 or 01. What is their difference, none of our employees will even remember. The only thing that will immediately catch your eye is the fuel pump harness. In -00 and -01 it had a different mounting method. So, if you decide to buy 10 instead of 00, make sure you have harness 2112-1139080-01.

21214 from 08.2009. 20 and their analogues. All cars starting with the M-ki (including Urbana) are equipped with the 20th EBN.