Checking fuel gauge sender 3G237: Audi A8 D4 (CDRA, CDSB, CDTA, CDTB, …)

🧭 Before you start

Fits: Audi A8 D4 (4H, 2010–2017)

• Special tools named: V.A.G 1561/22

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• The remaining material serves as a bonding surface when applying the new adhesive sealing material.

🔧 Engine codes this applies to

📋 Procedure

1. Observe safety precautions .
2. Observe rules for cleanliness .
3. Move front left seat all the way forwards.
4. Remove rear seat bench or individual seat (left-side) General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
5. Cut insulating mat along perforation in area of cover for flange for fuel gauge sender 2G169 (underneath rear seat on left, as seen in direction of travel) with a pair of scissors and fold mat to the side.

6. Use electric cutterV.A.G 1561A and blade (L-shaped, 25.4 mm)V.A.G 1561/22 to cut through adhesive sealant around cover for flange.
7. Detach cover for flange.
8. Repair painted surfaces Paintwork manual.
9. Apply anti-corrosion coating as necessary Surface treatment/chemical materials.
10. Release retainer catch and unplug electrical connector (1) on flange.
11. Connect multimeter (resistance test) as shown in table.
12. Renew fuel gauge sender 3G237.
13. Install cover for flange.
14. 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.]
15. ⚠ Apply adhesive thoroughly to ensure safe bonding.Keep bonding surface clean and free from grease.Do not trim bonding surface until shortly before installation.Do not prime bonding surface and do not treat with cleaning fluid.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.
16. Apply new sealant bead onto trimmed-down adhesive sealant on cover for flange and fit cover.
17. Remove rear seat bench or individual seat General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats. [Note: To test the maximum and minimum resistance values for "“tank full”" and "“tank empty”", remove the fuel gauge sender and move the sender float all the way to its top or bottom position.The following values are obtained with the fuel gauge sender removed, due to the greater travel of the float arm:]
18. Connect multimeter (resistance test) as shown in table.
19. Install fuel gauge sender 3G237.

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