Fuel Level Sensor 2 (G169)

Fuel Level Sensor 2 (G169)

Special tools, testers and auxiliary items required

• Trim Removal Wedge (3409)

• Window Cutter (V.A.G 1561A)

• Blade (L-shaped, 25.4 mm) (V.A.G 1561/22)

• Wrench (T10202)

• Sealant, refer to the Parts Catalog

Removing

- Follow all safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Fuel Supply System.

Audi A6 Hybrid

- Remove the traction battery (A2).

Audi A7 Sportback

- Remove the front shelf.

Audi A6/A7 without Hybrid Drive

- Vehicles with folding rear seat backrest: fold the rear seat backrest forward.

- Remove the luggage compartment floor covering.






Danger of causing damage to other electronic components when disconnecting the battery.

• Complete the steps for disconnecting the battery.

- Disconnect the Ground (GND) cable - 2 - from the battery.

- Version 1 cover: remove the cover - 1 - using (3409) - arrow -.






- Version 2 cover: remove the locking flange cover - 1 - using (3409) from the retainers - arrows -.






All Vehicles






- Cut through the sealing around the locking flange cover using (V.A.G 1561A) and (V.A.G 1561/22).

- Remove the locking flange cover.

- Repair damaged painted surfaces.

- Apply corrosion protection if necessary.

- Remove the locking ring using the (T10202).






- Remove the locking flange through the opening in the fuel tank.

- Remove the seal through the opening in the fuel tank.

- Reach through the opening in the fuel tank, press the releases - arrows - and unlock fuel level sensor 2.






- Remove fuel level sensor 2 - 1 - upward and carefully remove it through the opening in the fuel tank.

• Be careful not to bend the floater arm on the fuel level sensor when removing it.

Installing

Install in reverse order of removal. Note the following:

• Tightening specification, refer to => [ Fuel Delivery Unit and Fuel Level Sensor Overview ] Fuel Delivery Unit and Fuel Level Sensor Overview.

• Replace the seal.

• Be careful not to bend the floater arm on the fuel level sensor when installing it.

- Insert fuel level sensor 2 into the fuel tank.

- Install fuel level sensor 2 into its mount and then push it down until it audibly latches.

- Install the new locking flange seal - 4 -. The seal must dry.






Risk of leaking.

• When inserting the sealing flange, sealing ring must not be damaged or crushed.

- Bring the locking flange into the installation position.

• The tab - 1 - on the locking flange must face the hole - arrow - in the fastener and between the tabs - 2 and 3 - on the fuel tank.

- Shortly before installing the locking flange cover, smooth out the rest of the sealant on the cover and on the floor panel with a carpet knife but do not remove it completely.

• The remaining material acts as an adhesive base for the new sealant that will be applied.

Danger of poor adhesion.

• Keep the adhesive surface free of dirt and grease.

• Cut back the adhesive surface shortly before installing.

• Do not prime the adhesive surfaces and do not treat them with cleaning solution.

• Applying primer is only necessary if a new locking flange cover will be used.

- Cut the sealant cartridge nozzle as shown in the illustration.






• Dimension - a - = 7 mm.

- Apply a new sealant bead to the smoothed sealant on the locking flange cover and insert the cover.

• Both holes in the cover face opposite the drive direction.

Audi A6/A7 without Hybrid Drive

- Connect the battery. Be sure to read the procedures after connecting the battery.

- Install the luggage compartment floor covering.

Audi A7 Sportback

- Install the front shelf.

Audi A6 Hybrid

- Install the traction battery.