Fuel Level Sensor 2: Installing

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Tightening Specifications FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW .

Installation Is In Reverse Order Of Removal, Note The Following:

NOTE:

Replace Sealing Ring And Union Nut.

-- Install suction line -1- until it engages audibly.

Fig 1: Carefully Remove Fuel Level Sensor

Courtesy of AUDI OF AMERICA, LLC

-- Connect Electrical Connector -2- And Make Sure It Engages.

NOTE:

When Inserting, Be Sure Not To Bend Floater Arm On Fuel Level Sensor 2 -G169-.

-- Carefully Insert Fuel Level Sensor 2 -G169- -3- In Fuel Tank Opening.

-- Stretch New Sealing Ring Over Locking Flange And Insert It In Groove On Fuel Tank.

-- Place Union Nut -1- On Your Left Arm And Push Locking Flange -2- Forcefully Into Installation Position With Your Left Hand -arrow-.

Fig 2: Place Union Nut On Your Left Arm And Push Locking Flange

Courtesy of AUDI OF AMERICA, LLC

Tab -4- On Locking Flange Must Lie Between Tabs -3- And -5- On Threaded Ring.

-- Slide Union Nut -1- Off Your Left Arm Using Your Right Hand While Your Left Hand Keeps Holding Locking Flange -2- Down Firmly -arrow-.

Fig 3: Slide Union Nut Off Your Left Arm Using Your Right Hand While Your Left Hand Keeps Holding Locking Flange Down Firmly

Courtesy of AUDI OF AMERICA, LLC

-- Position union nut -1- with your right hand so double ridge -5- on ribs is over lug -3- on locking flange (approximately "10 o'clock" position). This makes sure union nut engages at beginning of threads immediately when Tightening it -4-.

-- Press locking flange down firmly with a screwdriver -arrow-.

-- Turn union nut approximately 480° with your right hand until double ridge -1- is in approximately "2 o'clock position" while keeping locking flange pressed down firmly with your left hand.

Fig 4: Press Locking Flange Down Firmly

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

There Is A Risk Of The Locking Flange Threaded Connection Leaking.

Press Locking Flange Down Firmly When Tightening Union Nut So It Does Not Rotate Too.

-- Tighten union nut using a union nut tool:T40068 A .

Verification: The double ridge -1- must now be between "7 and 8 o'clock".

Fig 5: Double Ridge -1- Must Now Be Between "7 And 8 O'clock"
Courtesy of AUDI OF AMERICA, LLC

-- Shortly Before Installing Locking Flange Cover, Smooth Out Rest Of Sealant On Cover And On Body With A Carpet Knife But Do Not Remove It Completely.

NOTE:

The Remaining Material Acts As An Adhesive Base For The New Sealant That Will Be Applied.

CAUTION:

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 Sealant Cartridge Nozzle As Shown In The Illustration.

Fig 6: Checking Nozzle Tip Cutting Dimension

Courtesy of AUDI OF AMERICA, LLC

Dimension -a- = 7 mm.

-- Apply A New Sealant Bead To The Smoothed Sealant On The Locking Flange Cover And Insert Cover.

The Arrow On Cover Must Point In Direction Of Travel.

-- Install Loading Aid Frame. Refer To LUGGAGE COMPARTMENT TRIM PANELS .

-- Connect Battery And Observe Safety Precautions After Connecting Battery. Refer To BATTERY, DISCONNECTING AND CONNECTING .

-- After Installing Fuel Level Sensor 2 -G169-, Fill Vehicle With At Least 5 Liters Of Fuel.