Fuel Level Sensor 2 G169 , removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Observe safety precautions → Safety precautions when working on fuel supply system .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

To remove fuel level sensor 2 G169 , the fuel tank may only be filled to a maximum of ¹ /₄ . Drain fuel tank if necessary. Procedure → Fuel tank, draining .
Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

Fig 1: Pushing Cover Over Battery Toward Right And Removing It Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 2: Locating Battery Ground Strap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
Open fuel filler flap briefly and then close again.

Fig 3: Removing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.
Unbolt cover for left locking flange - arrows -.

Fig 4: Disconnecting Electrical Harness Connector At Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Fig 5: Pulling Fuel Line Off From Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull fuel line - arrow - off from left locking flange, by pressing release button.

CAUTION: The fuel level sensor 2 G169 may only be removed when fuel tank is maximum ¹ /₄ full. Otherwise, a large amount of fuel will spill out.

Fig 6: Removing/Installing Locking Ring With Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left locking ring using wrench T10202.
Carefully pull locking flange with Fuel Level Sensor 2 G169 and seal slightly out of fuel tank opening.

Fig 7: Identifying Fuel Line, Locking Flange, Fuel Level Sensor 2 G169 & Suction Jet Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove fuel line - 1 - from fuel tank.
Pivot locking flange - 2 - with fuel level sensor 2 G169 - 3 - and suction jet pump - 4 - out of fuel tank opening.

NOTE:

When removing, be sure not to bend floater arm of fuel level sensor 2 G169.

Unclip suction jet pump from locking flange with Fuel Level Sensor 2 G169.

Fig 8: Press Release Buttons And Separate Fuel Hose At Y-Fitting

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press release buttons - arrows - and separate fuel hose at the Y-fitting.
Remove locking flange with fuel level sensor 2 G169.