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.
Follow the guidelines for clean working conditions.
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.
Electrical Equipment 27 Removal and Installation .
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,
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.