Checking fuel gauge sender G (bottom right sender): Audi 4.2 (BUJ, BYH, CMPA, CNDA, …)

Checking
fuel gauge sender
G
(bottom right sender)
Special tools and workshop equipment required
Removal lever
80-200
Hand-held multimeter
V.A.G 1526 E
Auxiliary measuring set
V.A.G 1594D
Procedure
Move seats as far forward as possible and tip down backrests.
Caution
To prevent irreparable damage to the electronic components when disconnecting the battery:
Observe notes on procedure for disconnecting the battery.
With ignition switched off, disconnect earth cable
arrow
at battery
Electrical system
Rep. gr.
27
.
R8 GT:
Remove rollover bars
General body repairs, interior
Rep. gr.
69
.
R8 Coupé and R8 GT:
Remove rear shelf
Rep. gr.
70
.
Remove side trim
Rep. gr.
70
.
Unscrew positive wire
4
.
Unplug electrical connectors
3
at connector point, detach connector point from bracket for control units and move connector point to the side.
Detach relay and fuse holder (rear right) from bracket for control units
arrows
and move relay and fuse holder aside.
Note
Disregard
items 1, 2, 5
.
Unplug electrical connectors for control units, unbolt bracket for control units
arrows
and remove bracket from vehicle.
Pry electrical wiring harness off base of back panel using
removal lever
80-200
and move harness clear.
R8 Spyder:
Remove convertible roof unit
Rep. gr.
61
.
All vehicles (continued):
Fold back insulating mat above cover for fuel tank flange.
Unscrew bolts
1 ... 4
and remove cover for flange on fuel tank (right-side).
Unplug electrical connector
arrow
on flange (right-side).
Note
Disregard
items 1, 2, 3
.
Connect multimeter (resistance test) between contacts
2
and
3
.
In order to test the maximum and minimum resistance values for
“tank full”
and
“tank empty”
, remove the
fuel gauge sender
G
Chapter
and move the float all the way to its top or bottom position.
Sender at bottom stop: approx. 994 Ω.
Sender at top stop: approx. 57.1 Ω.
Note
If the resistance is 0 Ω, there is a short circuit. If the resistance is ∞ Ω, there is an open circuit in the wiring.
Installation is carried out in the reverse order; note the following:
Tightening torques
Chapter
“
Exploded view - fuel gauge senders
”
.
Fig.
“Cover for flange on fuel tank - tightening torque”
.
Check sealing cord
1
at cover for fuel tank flange for damage.
Renew sealing cord if necessary; sealing cord
Electronic parts catalogue
.
Install connector point and relay and fuse holder (rear right)
Electrical system
Rep. gr.
97
.
R8 Spyder:
Install convertible roof unit
Rep. gr.
61
.
All vehicles (continued):
Connect battery and perform steps required after connecting battery
Electrical system
Rep. gr.
27
).