Home ReviewsRefund
Home/Audi/A4/Audi A4 B8 (2007-2012)/Repair manual/2.0l - Fuel Supply System - Engine Code(s): Caeb (avant)/FUEL LEVEL SENSOR 2 -G169
Contents Wiring diagrams Section: 2.0l - Fuel Supply System - Engine Code(s): Caeb (avant) All sections

FUEL LEVEL SENSOR 2 -G169 Audi A4 B8

2.0l - Fuel Supply System - Engine Code(s): Caeb (avant) 10 illustrations ~680 words

FUEL LEVEL SENSOR 2 -G169

Special tools and workshop equipment required

  1. Window Cutter V.A.G 1561A
  2. Blade (L-shaped, 25.4mm) V.A.G 1561/22
  3. Fuel Tank Sender Unit Tool T40068 A
  4. Sealant.

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

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

WARNINGDanger 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 1 / 4 full.

Empty the fuel tank if necessary. Refer to FUEL TANK, DRAINING .

CAUTIONDanger of causing damage to other electronic components when disconnecting the battery. Complete the steps for disconnecting the battery.

Disconnect the battery. Refer to Removal and Installation .

Fold the rear bench seat back rest forward.

A4 Sedan, A5 Cabrio and Coupe

Remove the loading aid frame. Refer to Removal and Installation .

A4 Avant

Remove the front luggage compartment floor (vehicle tool box). Refer to Removal and Installation .

All Vehicles

Scheme 243

Scheme 243
Scheme 243

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.

Disconnect the vent lines -1, 2 and 3- on the locking flange by pressing the release buttons.

Scheme 244

Scheme 244
Scheme 244

Scheme 245

Scheme 245
Scheme 245
WARNINGDanger 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 1 / 4 full.

Use a T40068 A to remove the union nut -arrow-.

Note. The plastic catch on the threaded ring breaks off when the union nut is loosened.

Carefully remove the fuel level sensor 2 -3- from the fuel tank opening.

Scheme 246

Scheme 246
Scheme 246

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

Disconnect the connector -2- by pressing the release -arrow A-.

Press the bracket together with needle nose pliers -B arrows- and remove the suction line -1-.

  1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR OVERVIEW»(/audi/a4/b8-2007-2012/remont/fuel-system/#20l-fuel-supply-system-engine-codes-caeb-avant) .

Install in reverse order of removal. Note the following

Note. Replace the sealing ring and the union nut.

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

Connect the electrical connector -2- and make sure it engages.

Note. When inserting, be sure not to bend floater arm on fuel level sensor 2.

Carefully insert the fuel level sensor 2 -3- in the fuel tank opening.

Stretch the new sealing ring over the locking flange and insert it in the groove on the fuel tank.

Place the union nut -1- on your left arm and push the locking flange -2- forcefully into installation position with your left hand -arrow-.

Scheme 247

Scheme 247
Scheme 247
  1. The tab -4- on the locking flange must be between the tabs -3 and 5- on threaded ring.

Slide the union nut -1- off your left arm using your right hand while your left hand keeps holding the locking flange -2- down firmly -arrow-.

Scheme 248

Scheme 248
Scheme 248

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

Press the locking flange down firmly -arrow-.

Scheme 249

Scheme 249
Scheme 249

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

Scheme 250

Scheme 250
Scheme 250
CAUTIONThere is a risk of the locking flange threaded connection leaking. Press the locking flange down firmly when tightening the union nut so it does not rotate too.

Tighten the union nut using T40068 A.

Scheme 251

Scheme 251
Scheme 251
  1. Verification: The double ridge -1- must now be between "7 and 8 o'clock".

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.

Note. The remaining material acts as an adhesive base for the new sealant that will be applied.

CAUTIONDanger 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.

Scheme 252

Scheme 252
Scheme 252
  1. Dimension -a- = 7 mm.

Apply a new sealant bead to the smoothed sealant on the locking flange cover and insert the cover.

  1. The arrow on the cover must point in the direction of travel.

Install the loading aid frame. Refer to Removal and Installation .

Connect the battery. Be sure to read the procedures after connecting the battery. Refer to Removal and Installation .

After installing the fuel level sensor 2, fill the vehicle with at least 5 liters of fuel.