Audi Workshop Service and Repair Manuals

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

t  Special wrench -T10202- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 1/4 full when removing the flange. Drain the tank if necessary. Procedure → Chapter. –  Briefly open filler cap for fuel tank and close again.

–  Remove rear seat bench → Rep. Gr.72. –  Unscrew cover for flange (right-side) -arrows-.

–  Unplug electrical connectors -1- and -2- at flange.

WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. –  Disconnect fuel hose -arrow- from flange (right side of vehicle). Vehicles with auxiliary heater: –  In addition, disconnect fuel line leading to metering pump for auxiliary heater by pressing release tab.

All models:   Caution The fuel tank must not be more than 1/4 full when opening the flange. Otherwise a large amount of fuel will escape. –  Unscrew locking ring using wrench -T10202-.

–  Detach flange with seal from fuel tank opening. –  Unplug electrical connector -arrow- on inside of flange.

–  Press retaining tab, and at the same time pull fuel gauge sender -G- out of baffle housing guide -arrows-.   Note The baffle housing is shown without fuel tank for illustration purposes.

Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seal. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Insert fuel gauge sender -G- into guide on outer section of baffle housing and press down until it clicks into place -arrow-.

–  Attach electrical connector -arrow- to inside of flange.

–  Install new seal for flange (seal must be installed dry). –  Move flange to installation position. l  Lug -2- on flange must be between tabs -1- and -3- on fuel tank.   Note The -arrow- points in direction of travel.

–  Tighten locking ring. Vehicles with auxiliary heater: –  Let auxiliary heater run with full load for 10 minutes to bleed fuel supply pipe going to metering pump. Tightening torque

Component	Nm
Locking ring for fuel delivery unit	145