Fuel Level Sensor 3 (G237)
Fuel Level Sensor 3 (G237)
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)
• 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 3/4 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 Ground (GND) cable - 2 - from the battery.
- Remove the luggage compartment rear trim panel..
- Remove the left infotainment control module, if equipped.
- Remove the left control module bracket.
- Remove the rear storage compartment.
- Fold the insulation mat near the locking flange cover 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.
- Press the release button and remove the bleed line - 1 -.
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 3/4 full.
- Remove the locking ring using the (T10202).
- Remove the locking flange - 3 - through the opening in the fuel tank.
- Press the release button and disconnect the bleed line - 2 -.
- Remove the seal - 1 - through the opening in the fuel tank.
- Disconnect the connector from fuel level sensor 3.
- Remove the locking flange and fuel level sensor 3 - 4 - 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 the locking flange and fuel level sensor 3 - 4 - into the fuel tank.
- Connect the electrical connector and make sure it engages.
- Install the breather line - 2 - until it audibly latches.
- Install the new locking flange seal - 1 -. The seal must dry.
- Insert the locking flange - 3 - into the fuel tank.
- Bring the locking flange into the installation position.
Risk of leaking.
• When inserting sealing flange, sealing ring must not be damaged or crushed.
• The tab - 2 - on locking flange must lie between tabs - 1 and 3 - on the fuel tank.
• The arrow on the locking flange must point in direction of travel.
- Attach the breather line so that it audibly latches.
- 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 storage compartment.
- Install the infotainment control module.
- Install the left control module bracket.
- Install the luggage compartment rear trim panel..
- Connect the battery. Be sure to read the procedures after connecting the battery.