Removing and installing fuel gauge sender 2G169 - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive — AUDI

🧭 Before you start

Fits: Audi A5 Cabriolet (8F), Audi A5 (8T, 2007–2016), 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: Rest-of-world vehicles , USA vehicles .
• 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 2 G169.
• 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 T40068A.

🔧 Engine codes this applies to

📋 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: Rest-of-world vehicles , USA vehicles .
4. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.
5. Fold backrest of rear seat forwards.

6. Remove mounting frame for loading aid General body repairs, interior70Luggage compartment trim panels; Removing and installing mounting frame for loading aid.
7. Remove luggage compartment floor (front) (holder for vehicle tool kit) General body repairs, interior70Luggage compartment trim panels; Exploded view - luggage compartment floor.
8. Remove fuel delivery unit .
9. 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.
10. Detach cover for flange.
11. Repair painted surfaces Paintwork manual.
12. Apply anti-corrosion coating as necessary Surface treatment/chemical materials.
13. Disconnect breather lines (1 and 2) on flange .
14. Disconnect breather lines (1, 2, 3) on flange .
15. ⚠ 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 T40068A(arrow). [Note: The plastic detent on the threaded ring will break off when the union nut is unscrewed - this can be disregarded.]
16. Lift out flange with fuel gauge sender 2G169 and move electrical wiring clear.
17. Unclip fuel gauge sender 2G169(item 1) from flange. [Note: When removing, make sure you do not bend float arm of fuel gauge sender 2 G169.]
18. Clip fuel gauge sender 2G169(item 1) onto flange.
19. Route electrical wiring from fuel gauge sender 2G169 to fuel delivery unit. [Note: Renew seal and union nut.When installing, make sure you do not bend float arm of fuel gauge sender 2 G169.]
20. Carefully insert fuel gauge sender 2G169 into opening in fuel tank.
21. Slip new seal onto flange and insert in groove on fuel tank.
22. Slip union nut (1) over your left arm and press flange (2) firmly into installation position (arrow) with your left hand.
23. 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).
24. 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.
25. Keep pressing flange downwards firmly (arrow).
26. 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.
27. ⚠ 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 T40068A.
28. 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.]
29. ⚠ 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.
30. Apply new sealant bead onto trimmed-down adhesive sealant on cover for flange and fit cover.
31. Install fuel delivery unit .
32. Install mounting frame for loading aid General body repairs, interior70Luggage compartment trim panels; Removing and installing mounting frame for loading aid.
33. Connect battery and perform steps required after re-connecting battery Electrical system27Battery; Disconnecting and connecting battery.
34. Put at least 5 litres of fuel into tank after installing fuel gauge sender 2 G169.

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