Fuel Level Sensor 2 -G169-, Removing and Installing

Fuel Level Sensor 2 -G169-, Removing And Installing

(AWD Models)

Special tools, testers and auxiliary items required
- Wrench for tank sensor 3087
- Torque wrench V.A.G 1332

NOTE:
- To remove locking ring, fuel tank may be a maximum of 1/4 full.
- Empty right chamber of fuel tank if necessary.
- Read safety precautions and rules of cleanliness before beginning work.

Removing
- Check whether a coded radio is installed. If necessary, obtain radio anti-theft coding.
- Switch off ignition and all electrical consumers.
- Disconnect battery Ground (GND) strap.
- Open fuel filler flap briefly and then close again.
- Remove rear seat bench.
- Remove Fuel Level Sensor 2 -G169-.







- Carefully disconnect 2-pin connector - arrow - from Fuel Level Sensor 2 -G169- and remove it.







- Remove locking ring using special wrench for tank sensor 3087.
- Carefully pull Fuel Level Sensor 2 -G169- slightly out of fuel tank opening.
- Disconnect connector to Fuel Pump (FP) flange (in direction of travel, right) from inside of flange.
- If necessary, siphon fuel from left chamber of fuel tank.







- Reach into fuel tank and disengage catches - arrows - at bottom of the suction jet pump -2-
NOTE: Sensor is shown without fuel tank for the sake of illustration.

Installing Installation is performed in reverse order of removal. Note the following:

NOTE: Do not bend floater arm of Fuel Level Sensor 2 -G169- when installing.







- Insert Fuel Level Sensor 2 -G169- -1- into fuel tank.
- Connect suction jet pump -2- to sensor at inside of fuel tank. Catches must engage.
- Connect 2-pin connector to inside of flange.
- Insert new seal for flange, dry, into opening of fuel tank and coat only inner side (equipment flange) with fuel.







- Check installation position of Fuel Level Sensor 2 -G169-.
- Marking on sensor -2- must align with marking on fuel tank -1-.
- Check sealing ring for correct positioning.







- Tighten locking ring using wrench for tank sensor 3087.
- Tightening torque: 145 Nm
- Connect electrical connector.
- Check Diagnostic Trouble Code (DTC) memory of all control modules, repair all stored malfunctions, and erase DTC memory Vehicle Diagnosis, Testing and Information System VAS 5051; Guided Fault Finding; Vehicle System Test, or Vehicle Diagnosis and Service Information System VAS 5052; On Board Diagnostic (OBD).