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, 25.4mm) (V.A.G 1561/22)
• Wrench (T10202)
• Scissors
• Sealant, refer to the Electronic Parts Catalog (ETKA)
Removing
- Follow all safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.
- Follow the guidelines for clean working conditions. Refer to => [ 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.
- Move the left front seat all the way forward.
- Remove the rear bench seat or the left lower seat frame/rear seat backrest.
Danger of causing damage to the other electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Disconnect the Ground (GND) cable - 2 - from the battery.
- Cut the insulation mat near the locking flange cover along the perforation with scissors and fold it to the side.
- 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 connector - 1 - on the locking flange.
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 (T10202).
- Remove the locking 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 -.
- Reach into the fuel tank, press the tab - 2 - - arrow - and release fuel level sensor 2.
- Remove the fuel level sensor 2 - 1 - from its mount on the baffle housing.
- Remove the fuel level sensor 2 and its electric wires from 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 Overview ] Fuel Delivery Unit Overview.
• Replace 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.
- Connect the connectors and make sure they are secure.
- Install a new dry locking flange sealing ring.
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 - 2 - on the left locking flange must be located between the tabs - 1 and 3 - on the fuel tank.
• The arrow on the locking flange must point in direction of travel.
- Connect the electrical connector and make sure it engages.
- 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.
• Both holes in the cover face opposite the drive direction.
- Install the rear bench seat or the lower seat frame/rear seat backrest.
- Connect the battery. Be sure to read the procedures after connecting the battery.