Fuel Level Sensor 2 -G169-, Removing and Installing (AWD)

Fuel Level Sensor 2 -G169-, Removing And Installing

Special tools, test equipment and auxiliary items







- 3087 Fuel Tank Wrench

Removing
- For the removal of the fuel sender the fuel tank should be a maximum 1/4 full. Drain fuel tank if necessary.

CAUTION: After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar(R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

- Vehicles with coded radio/navigation system (RNS) coding, refer to the Owner's Manual, if necessary.

Audi A6:

CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.







- Remove cover above battery -arrows-.

NOTE: On vehicles without battery cover: Remove plenum cover.







- Disconnect battery Ground (GND) strap -arrow-, with ignition switched off.

Audi RS6:







- Turn locks -arrow- counterclockwise and remove cover -1-
- Remove cover -1- off upward.







- With ignition switched off, disconnect battery Ground (GND) cable -arrow-.

All:
- Open fuel filler cap briefly and close again
- Remove rear seat bench.







- Remove screws -arrows- for the cover.







- Carefully disengage 2-pin harness connector -arrow- and disconnect. (4-pin harness connector shown).

WARNING: When removing fuel level sensor 2 the fuel tank should only be 1/4 full. Otherwise large quantities of fuel escape.







- Remove closing ring (driver side) using 3087 Fuel Tank Wrench.
- Remove fuel level sensor 2 together with seal slightly out of opening in tank.
- Disconnect harness connectors for sender for fuel gauge at inside (closing flange) of fuel level sensor 2.







- Reach into tank and disconnect fuel lines to suction jet pump -2- by releasing tabs -arrows-.


NOTE: For better illustration purpose the accumulator is shown without fuel tank.

Installing
Installation is the reverse of removal, however note the following:

NOTE: Do not bend the fuel level sensor during installation.







- Connect harness connectors before installing fuel level sensor 2 into fuel tank.
- On inside of fuel tank install fuel lines to suction jet pump -2- into fuel level sensor 2.
Tabs must engage.
- Insert new seal for fuel level sensor 2 dry into opening for fuel tank.







- Consider the installation position of the fuel sender for fuel supply:
- Marking on fuel sender -2- must match marking on fuel tank -1-







- Tighten closing ring with 120 Nm (89 ft lb).
- Install fuel supply and return lines as previously marked.
- Install cover for closing flange with indentation over connector.

NOTE: With Battery re-connected, remember to activate electrical equipment (radio, clock, window switches) according to operating instructions.


- With ignition switched off, reconnect battery Ground (GND) strap.
- After reconnecting battery, insert radio code.
- Generate readiness code.

Finishing steps:
- Fill vehicle with fuel.
- Check entire resistance of fuel level sensor 2
- Specification: approximately 270 Ohm (Tank full)

Tightening torque

Torque Nm
Closing ring for fuel pump delivery module 145 Nm (106 ft lb)
Battery pole connections 5 Nm (44 in lb)