Audi Workshop Service and Repair Manuals

Removing and installing fuel gauge sender 2 -G169- Special tools and workshop equipment required

t  Electric cutter -V.A.G 1561A-

t  Blade (L-shaped, 25.4 mm) -V.A.G 1561/22-

t  Union nut tool -T40068 A- t  Adhesive sealant → Electronic parts catalogue Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness → Chapter.   WARNING Large amounts of fuel can escape. The fuel tank must not be more than 1/4 full when removing the fuel gauge sender, otherwise a large amount of fuel will escape. –  Drain fuel tank if necessary: Rest-of-world vehicles → Chapter, USA vehicles → Chapter.   Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect battery → Electrical system; Rep. gr.27. –  Fold backrest of rear seat forwards. A4 saloon, A5 Cabriolet and A5 Coupé: –  Remove loading frame → Rep. gr.70. A4 Avant: –  Remove luggage compartment floor at front (vehicle tool kit retainer) → Rep. gr.70.

All vehicles (continued): –  Use electric cutter -V.A.G 1561A- and blade (L-shaped, 25.4 mm) -V.A.G 1561/22- to cut through adhesive sealant around cover for flange. –  Detach cover for flange. –  Repair painted surfaces → Paintwork manual. –  Apply anti-corrosion coating as necessary → Surface treatment/chemical materials.

Rest-of-world vehicles: –  Disconnect breather pipes -1, 2- on flange (press release tabs).

USA vehicles: –  Disconnect breather pipes -1, 2, 3- on flange (press release tabs).

All vehicles (continued):   WARNING Large amounts of fuel can escape. The fuel tank must not be more than 1/4 full when removing the fuel gauge sender, otherwise a large amount of fuel will escape. –  Unscrew union nut using union nut tool -T40068 A--arrow-.   Note The plastic detent on the threaded ring will break off when the union nut is unscrewed - this can be disregarded.

–  Carefully take fuel gauge sender 2 -G169--item 3- out of opening in fuel tank.   Note When removing, make sure you do not bend float arm of fuel gauge sender 2 -G169-. –  Press release tab -arrow A- and unplug electrical connector -2-. –  Use long-nose pliers to compress catches -arrows B- and pull off suction pipe -1-. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following:   Note Renew seal and union nut.

–  Connect suction pipe -1- so it engages audibly. –  Plug in electrical connector -2- and make sure it is correctly engaged.   Note When installing, make sure you do not bend float arm of fuel gauge sender 2 -G169-. –  Carefully insert fuel gauge sender 2 -G169--item 3- into opening in fuel tank. –  Slip new seal onto flange and insert in groove on fuel tank.

–  Slip union nut -1- over your left arm and press flange -2- firmly into installation position -arrow- with your left hand. l  Lug -4- on flange must be between tabs -3- and -5- on threaded ring.

–  Take union nut -1- off your left arm with your right hand and at the same time keep pressing down flange -2- firmly with your left hand -arrow-. –  Position union nut -1- with your right hand in such a way that double ridge -5- on ribs aligns with lug -3- of flange (approx. „ten o'clock position“). This will make union nut engage immediately with beginning of thread -4- when tightening.

–  Keep pressing flange downwards firmly -arrow-. –  Turn union nut approx. 480° with your right hand until double ridge -1- is in approx. „two o'clock position“ and at the same time keep on pressing flange downwards firmly with your left hand.

Caution Take care to avoid leakage at flange. Press flange downwards firmly when tightening union nut to make sure flange does not also turn. –  Tighten union nut for flange using union nut tool -T40068 A-.

l  Checking: Double ridge -1- must now be aligned between „seven o'clock and eight o'clock position“. –  Just before re-installing cover for flange, trim down remaining adhesive sealing material on cover for flange and on body with carpet knife to give a smooth surface; do NOT remove sealant completely.   Note The remaining material serves as a bonding surface when applying the new adhesive sealing material.   Caution Apply adhesive thoroughly to ensure safe bonding. t  Keep bonding surface clean and free from grease. t  Do not trim bonding surface until shortly before installation. t  Do not prime bonding surface and do not treat with cleaning fluid. t  Application of primer is only required when fitting a new cover for flange.

–  Cut off tip of nozzle of adhesive sealant cartridge as shown in illustration. l  Distance -a- = 7 mm. –  Apply new sealant bead onto trimmed-down adhesive sealant on cover for flange and fit cover. l  Arrow on cover points in direction of travel. –  Install loading frame → Rep. gr.70. –  Connect battery (observe notes on procedure for connecting the battery → Electrical system; Rep. gr.27). –  Put at least 5 litres of fuel into tank after installing fuel gauge sender 2 -G169-.