Audi Workshop Service and Repair Manuals

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

t  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.

Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Slide cover above battery to the right -arrow 1- and lift off -arrow 2-.

–  With ignition switched off, disconnect earth strap -arrow- at battery. –  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 connector -arrow- at flange (right side of vehicle).   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.

–  Detach fuel line -1- from flange (press release tab). –  On vehicles with auxiliary heater, also disconnect fuel line -2- leading to metering pump for auxiliary heater (press release tab).

WARNING 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-.

–  Remove 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 Renew seal. –  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. –  Observe instructions for connecting battery → Rep. Gr.27. Tightening torque

Component	Nm
Locking ring for fuel delivery unit	145