Removing and installing fuel gauge sender 2G169 - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with four-wheel drive) — AUDI

🧭 Before you start

Fits: Audi A5 (8T, 2007–2016), Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015)

• Special tools named: V.A.G 1561/22
• Renewed: seal

Don't miss

• Danger! Fuel may 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 .
• The plastic detent on the threaded ring will break off when the union nut is unscrewed - this can be disregarded.
• When removing, make sure you do not bend float arm of fuel gauge sender 2 G169.
• Renew seal and union nut.When installing, make sure you do not bend float arm of fuel gauge sender 2G169.
• 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.

🔧 Engine codes this applies to

📐 38 workshop diagrams for CAGA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Observe safety precautions .
2. Observe rules for cleanliness .
3. ⚠ Danger! Fuel may 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 .
4. Fold backrest of rear seat forwards.
5. Remove mounting frame for loading aid General body repairs, interior70Luggage compartment trim panels; Removing and installing mounting frame for loading aid.

6. Remove luggage compartment floor (front) (holder for vehicle tool kit) General body repairs, interior70Luggage compartment trim panels; Removing and installing luggage compartment floor.
7. Remove fuel delivery unit .
8. 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.
9. Detach cover for flange.
10. Repair painted surfaces Paintwork manual.
11. Apply anti-corrosion coating as necessary Surface treatment/chemical materials.
12. On vehicles with SCR system: disconnect breather line on flange.
13. ⚠ Danger! Fuel may 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.]
14. Lift out flange (2) with fuel gauge sender 2G169(item 1) and move electrical wiring clear.
15. Unclip fuel gauge sender 2G169(item 1) from flange (2). [Note: When removing, make sure you do not bend float arm of fuel gauge sender 2 G169.]
16. Clip fuel gauge sender 2G169(item 1) onto flange (2).
17. Route electrical wiring from fuel gauge sender 2G169(item 1) to fuel delivery unit. [Note: Renew seal and union nut.When installing, make sure you do not bend float arm of fuel gauge sender 2G169.]
18. Carefully insert fuel gauge sender 2G169 into opening in fuel tank.
19. Slip new seal onto flange and insert in groove on fuel tank.
20. Slip union nut (1) over your left arm and press flange (2) firmly into installation position (arrow) with your left hand.
21. 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).
22. 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.
23. Keep pressing flange downwards firmly (arrow).
24. 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.
25. ⚠ 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.
26. 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.]
27. ⚠ 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.
28. Apply new adhesive sealant onto trimmed-down adhesive sealant on cover for flange and fit cover.
29. Install fuel delivery unit .
30. Install mounting frame for loading aid General body repairs, interior70Luggage compartment trim panels; Removing and installing mounting frame for loading aid.
31. Put at least 5 litres of fuel into tank after installing fuel gauge sender 2 G169.

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