Audi Workshop Service and Repair Manuals

Removing and installing fuel gauge sender 2 -G169- 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 fuel gauge sender 2 -G169-. Drain the tank if necessary. Procedure → Chapter. –  Briefly open filler cap for fuel tank and close again.

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

–  Unplug electrical connector -arrow- at flange (left side of vehicle).   WARNING t  The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. 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.

–  Disconnect fuel line -arrow- from flange (left side of vehicle) by pressing release tab.

Caution The fuel tank must not be more than 1/4 full when removing the fuel gauge sender 2 -G169-. Otherwise a large amount of fuel will escape. –  Unscrew locking ring using wrench -T10202- (left side of vehicle).

–  Carefully pull flange with fuel gauge sender 2 -G169- and seal just slightly out of opening in fuel tank. –  First pull fuel line -1- out of fuel tank. –  Swivel flange -2- with fuel gauge sender 2 -G169--item 3- and suction-jet pump -4- out of fuel tank opening.   Note When removing, make sure you do not bend float arm of fuel gauge sender 2 -G169-. –  Unclip suction-jet pump from flange with fuel gauge sender 2 -G169-.

–  Press release tabs -arrows- and disconnect fuel hose from connector. –  Remove flange with fuel gauge sender 2 -G169-. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seal. t  When installing, make sure you do not bend float arm of fuel gauge sender 2 -G169-. t  Ensure that fuel hose is securely connected.

–  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. Tightening torque

Component	Nm
Locking ring for flange of fuel gauge sender 2 -G169-	145