Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING: Removing

WARNING: This page is about a different variant/trim than selected.

Follow all safety precautions, refer to WORKING ON FUEL SYSTEM .

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

The fuel tank must be completely empty to remove the fuel level sensor 2 -G169-. Procedure to empty the fuel tank FUEL TANK, DRAINING .

-- Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats, refer to Seat Frames .

Fig 1: Cut The Floor Covering Along The Perforation

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the left side with a carpet knife -1-.

-- Fold carpet cut-out to side -arrow-.

Fig 2: Identifying Locking Flange Cover - Tightening Specifications

Courtesy of AUDI OF AMERICA, LLC

-- Remove the nuts -1 to 4- and remove left locking flange cover.

-- Disconnect electrical harness connector -arrow- at left locking flange.

Fig 3: Connecting Connector -Arrow- At Left Locking Flange

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect fuel lines -2 and 3-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Continuation for All Vehicles

Fig 4: Identifying Removal Of Locking Ring With T10202

Courtesy of AUDI OF AMERICA, LLC

-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

Vehicles with 3.0L (V6)/4.2L (V8) Engine through 05/2010:

Fig 5: Fuel Tank Connectors

Courtesy of AUDI OF AMERICA, LLC

-- Remove the locking flange with the seal from the opening in the fuel tank and disconnect the connectors -1 and 2- on the bottom of the locking flange.

Vehicles with 3.0L (V6)/4.2L (V8) Engine from 06/2010

Fig 6: Connecting Electrical Connector -2- Underneath Left Locking Flange -3-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the locking flange -3- with the seal -1- from the opening in the fuel tank and disconnect the connector -2- on the bottom of the locking flange.

Continuation for All Vehicles

Fig 7: Identifying Removal Of Fuel Level Sensor 2 Out Of Guide -4- -Arrow 2- By Pressing Release Tab -Arrow 1-

Courtesy of AUDI OF AMERICA, LLC

-- Reach into the fuel tank opening, press the locking tab in direction of -arrow 1- and remove the Fuel Level Sensor 2 -G169- -3- from the guide -4- in direction of -arrow 2-.