Removing and installing fuel gauge sender 2 G169 — AUDI

Removing and installing
fuel gauge sender 2
G169
Special tools and workshop equipment required
Union nut tool
T40068 A
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 2
G169
, otherwise a large amount of fuel will escape. Drain the tank if necessary. Procedure
Chapter
.
Caution
To prevent damage to the electronic components when disconnecting the battery:
Observe notes on procedure for disconnecting the battery
Rep. Gr.
27
.
Switch off ignition.
Saloon:
Fold up luggage compartment floor lining.
Avant:
Remove luggage compartment load surface
1
and spare wheel well cover plate
2
.
All vehicles:
Use screwdriver
2
to release retaining clips
arrows
and detach cover
1
.
Disconnect earth cable at negative terminal of battery
arrow
.
Remove rear seat bench
Rep. Gr.
72
.
Detach cover for flange (left-side)
arrows
.
WARNING
Large amounts of fuel can escape.
The fuel tank must not be more than
1
/
4
full when removing the fuel gauge sender 2
G169
, otherwise a large amount of fuel will escape.
Use
union nut tool
T40068 A
to unscrew union nut (left-side)
arrow
.
Note
The plastic detent on the threaded ring will break off when the union nut is unscrewed - this can be disregarded.
Carefully pull
fuel gauge sender 2
G169
item 1
together with suction-jet pump
2
just slightly out of opening in fuel tank.
Note
When removing, make sure you do not bend float arm of fuel gauge sender 2
G169
.
Unclip suction-jet pump from flange.
Unplug electrical connector
1
.
Use screwdriver to release retaining tabs
arrows
and detach
fuel gauge sender 2
G169
.
Installing
Tightening torque
Chapter
Installation is carried out in the reverse order; note the following:
Note
Renew seal and union nut.
Insert
fuel gauge sender 2
G169
into guides on flange and press in until it engages.
Plug in electrical connector and check that it has engaged properly.
Clip suction-jet pump
3
onto flange
2
, so that you hear it click into place.
Make sure that fuel supply pipe is connected to supply pipe for suction-jet pump with at least 3 cable ties.
Note
When installing, make sure you do not bend float arm of fuel gauge sender 2
G169
.
Carefully insert
fuel gauge sender 2
G169
into opening in fuel tank.
Slip new seal
1
over flange and insert it 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.
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.
Turn locking ring approx. 390° with your right hand until double ridge
1
is in approx. twelve 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.
Use
union nut tool
T40068 A
to tighten union nut for flange (left-side).
Tightening torque: 120 Nm.
Checking: Double ridge
1
must now be aligned between five o'clock and six o'clock position.
Install rear seat bench
Rep. Gr.
72
.
Connect battery. Observe notes on procedures required after connecting battery
Rep. Gr.
27
.
Put at least 5 litres of fuel into tank after installing
fuel gauge sender 2
G169
.