Fuel Level Sensor 2 -G169-, Removing And Installing: Removing

-- Follow all safety precautions, refer to SAFETY PRECAUTIONS .

-- Follow the rules for clean working conditions, refer to CLEAN WORKING CONDITIONS .

WARNING:

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.

-- If required, empty the fuel tank, refer to FUEL TANK, DRAINING .

-- Move the left front seat all the way forward.

-- Remove the rear bench seat or left rear single seat, refer to Rear Seats .

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

-- Disconnect the battery Ground (GND) cable -2-, refer to BATTERY .

Fig 1: Disconnecting Battery

Courtesy of AUDI OF AMERICA, LLC

-- Cut the insulation mat near the sealing flange cover (in direction of travel on the left side under the rear seat) with scissors along the perforation and fold to the side.

Fig 2: Cut Through Sealing Around Locking Flange Cover With VAG 1561A And VAG 1561/22

Courtesy of AUDI OF AMERICA, LLC

-- Cut through the adhesive rings all the way around the sealing flange cover using Window Cutter VAG 1561A and Window Cutter - L Blade (2 pc.) VAG 1561/22.

-- Remove the sealing flange cover.

-- Repair any damaged painted surfaces.

-- Apply corrosion protection if necessary.

-- Release the connector safety catch, and disconnect the connector -1- on the sealing flange.

Fig 3: Identifying Sealing Flange Connector

Courtesy of AUDI OF AMERICA, LLC

Fig 4: Identifying Fuel Sending Unit Wrench

Courtesy of AUDI OF AMERICA, LLC

WARNING:

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.

-- Remove the locking ring using the Wrench - Fuel Sending Unit T10202.

-- Remove the sealing flange -1- through the opening in the fuel tank.

-- Remove the seal -4- through the opening in the fuel tank.

-- Disconnect the connectors -2 and 3- by releasing the connector safety catch.

Fig 5: Identifying Sealing Flange, Connectors And Seal

Courtesy of AUDI OF AMERICA, LLC

-- Reach into the fuel tank and release the Fuel Level Sensor 2 -G169- by pressing the release -2- in direction of -arrow-.

Fig 6: Releasing Fuel Level Sensor 2

Courtesy of AUDI OF AMERICA, LLC

-- Pull the Fuel Level Sensor 2 -G169- -1- upward out of the baffle housing mount.

-- Remove the Fuel Level Sensor 2 -G169- with wires carefully out of the fuel tank.

NOTE:

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