Audi Workshop Service and Repair Manuals

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

t  Union nut tool -3217-

t  Hose clip pliers -V.A.G 1275- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 3/4 full when removing fuel gauge sender -G-. Drain the tank if necessary. Procedure → Chapter. Saloon: –  Detach trim in luggage compartment. –  If necessary, fold forward right backrest of rear seat bench. Avant: –  Remove left-side section of backrest (1/3 section) → Rep. Gr.72. –  Remove left-side trim in luggage compartment and anti-soiling tray → Rep. Gr.70.

All models: –  Unscrew cover for flange -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. –  Detach fuel supply hose -1- from flange. –  Detach fuel return pipe -2- from flange (press release tab). Vehicles with auxiliary heater: –  In addition, disconnect fuel line leading to metering pump for auxiliary heater (press release tab).

All models:   Caution The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Otherwise a large amount of fuel will escape. –  Use union nut tool -3217- to unscrew union nut.

–  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  Arrow -2- on flange must align with arrow -1- on fuel tank.

–  Tighten union nut for flange.

–  Install fuel supply hose -1- and fuel return pipe -2-. –  Plug in electrical connectors. 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
Union nut for fuel delivery unit	80