Audi Workshop Service and Repair Manuals

Removing and installing fuel gauge sender -G- Special tools and workshop equipment required

t  Spanner for union nuts -3217- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 3/4 full when removing the fuel gauge sender. Drain the tank if necessary. Procedure → Chapter.

–  Fold down the rear seat bench or remove the rear seat bench → Rep. Gr.72. –  Fold back lining under rear set. –  Turn cover for fuel gauge sender in -direction of arrow- and detach cover.

–  Unplug electrical connector -arrow- at flange.

–  Mark fuel supply pipe -1- and fuel return pipe -2-.   WARNING t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Detach both pipes from flange (press release tabs). Vehicles with supplementary heater: –  Disconnect fuel pipe leading to metering pump for supplementary heater.

All models: –  Use spanner for union nut -3217- to unscrew union nut. –  Pull fuel gauge sender with fuel collector and seal out of opening in fuel tank.   Note t  When removing fuel collector, make sure you do not bend float arm of fuel gauge sender -G-. t  Keep in mind that the fuel collector still contains fuel.   Caution First release retainer tabs on connector contact before detaching electrical connectors on fuel gauge sender -G-.

–  Release retainer tabs on electrical connectors -1- and -2- and then detach electrical connectors. –  Lift retaining tabs -3- and -4- with a screwdriver and pull fuel gauge sender -G- off downwards -arrow-. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seal. t  Take care not to bend the fuel gauge sender when fitting fuel collector. –  Insert fuel gauge sender -G- into guides on fuel collector and press upwards until sender clicks into place. –  Plug in electrical connectors and check that they have engaged properly.

–  Make sure new seal for flange is installed dry. –  Insert fuel collector in fuel tank. –  Press flange down against spring pressure, and turn flange to installation position. l  Arrow -2- on flange must align with arrow -1- on fuel tank.

–  Use union nut tool -3217- to tighten union nut.

–  Connect fuel pipes. l  Fit blue return pipe -2- onto connection marked “R”. l  Fit black supply pipe -1- onto connection marked “V”. Tightening torque

Component			Nm
Union nut for fuel collector			80