Fuel Level Sensor 2 (G169)
Fuel Level Sensor 2 (G169)
Special tools, testers and auxiliary items required
• Window Cutter (V.A.G 1561A)
• Blade (L-shaped, 25.4 mm) V.A.G 1561/22 (V.A.G 1561/22)
• Fuel Tank Sender Unit Tool (T40068 A)
• Sealant, refer to the Parts Catalog
Removing
- Follow all safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.
- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Danger due to escaping fuel.
• To prevent large quantities of fuel from leaking from the fuel level sensor when removing, the fuel tank may only be a maximum of 1/4 full.
- Empty the fuel tank if necessary, refer to => [ Fuel Tank, Draining ] Procedures.
Danger of causing damage to other electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Disconnect the battery.
- Fold the rear bench seat backrest forward.
A4 Sedan, A5 Cabrio and Coupe
- Remove the loading aid frame.
A4 Avant
- Remove the front luggage compartment floor (vehicle tool box)..
All Vehicles
- Cut through the sealing around the locking flange cover with the (V.A.G 1561A) and (V.A.G 1561/22).
- Remove the locking flange cover.
- Repair damaged painted surfaces.
- Apply corrosion protection if necessary.
- Disconnect the vent lines - 1, 2 and 3 - on the locking flange by pressing the release buttons.
Danger due to escaping fuel.
• To prevent large quantities of fuel from leaking from the fuel level sensor when removing, the fuel tank may only be a maximum of 1/4 full.
- Use a (T40068 A) to remove the union nut - arrow -.
• When union nut is loosened, plastic catch on threaded ring breaks off - ignore.
- Carefully remove the fuel level sensor 2 - 3 - from the fuel tank opening.
• When removing, be sure not to bend floater arm of fuel level sensor 2.
- Disconnect the connector - 2 - by pressing the release - arrow A -.
- Press the bracket together with needle nose pliers - B arrows - and remove the suction line - 1 -.
Installing
• Tightening specification, refer to => [ Fuel Delivery Unit and Fuel Level Sensor Overview ] Fuel Delivery Unit and Fuel Level Sensor Overview.
Install in reverse order of removal. Note the following:
• Replace the sealing ring and the union nut.
- Install the suction line - 1 - until it engages audibly.
- Connect the electrical connector - 2 - and make sure it engages.
• When inserting, be sure not to bend floater arm on fuel level sensor 2.
- Carefully insert the fuel level sensor 2 - 3 - in the fuel tank opening.
- Stretch the new sealing ring over the locking flange and insert it in the groove on the fuel tank.
- Place the union nut - 1 - on your left arm and push the locking flange - 2 - forcefully into installation position with your left hand - arrow -.
• The tab - 4 - on locking flange must lie between tabs - 3 and 5 - on threaded ring.
- Slide the union nut - 1 - off your left arm using your right hand while your left hand keeps holding the locking flange - 2 - down firmly - arrow -.
- Position the union nut - 1 - with your right hand so the double ridge - 5 - on the ribs is over the lug - 3 - on the locking flange (approximately "10 o'clock" position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it - 4 -.
- Press the locking flange down firmly with a screwdriver - arrow -.
- Turn the union nut approximately 480° with your right hand until the double ridge - 1 - is in approximately "2 o'clock position" while keeping the locking flange pressed down firmly with your left hand.
There is a risk of the locking flange threaded connection leaking.
• Press the locking flange down firmly when tightening the union nut so it does not rotate too.
- Tighten the union nut using (T40068 A).
• Verification: The double ridge - 1 - must now be between "7 and 8 o'clock".
- Shortly before installing the locking flange cover, smooth out the rest of the sealant on the cover and on the body 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.
• The arrow on the cover must point in the direction of travel.
- Install the loading aid frame..
- Connect the battery. Be sure to read the procedures after connecting the battery.
- After installing the fuel level sensor 2 , fill the vehicle with at least 5 liters (5.28 quarts) of fuel.