Removing and installing fuel gauge sender 3 G237 (tubular sender, left-side) — AUDI

Removing and installing fuel gauge sender 3
G237 (tubular sender, left-side)
Special tools and workshop equipment required
Vehicles from approx. 11.2002:
Wrench
T10202
Removing
Observe safety precautions (see the separate procedure).
Observe rules for cleanliness (see the separate procedure).
The left fuel tank chamber must not be more than (1)
/ (3) full when removing the tubular sender. Procedure for draining the fuel tank (see the separate procedure).
Caution
Observe notes on procedure for disconnecting the battery.
With ignition switched off, disconnect battery earth cable (arrow) (repair group 27).
Briefly open filler cap for fuel tank and close again.
Remove luggage compartment floor covering.
Note
For removing and installing tubular sender, take tool kit and spare wheel out of luggage compartment. You can then sit or kneel in the spare wheel well.
Detach cover for flange (left-side) (arrows).
Unplug electrical connectors (1) and (2) on flange (left-side).
Vehicles up to approx. 10.2002:
Remove bolts (arrows) and take off locking ring for flange (left-side).
Vehicles from approx. 11.2002 onwards:
Unscrew locking ring using wrench
T10202.
All vehicles (continued):
Detach flange and remove seal.
Unplug electrical connectors
1 ... 3 on underside of flange (left-side).
Working through left fuel tank opening, press release tabs (arrows) and detach fuel supply line (2) and fuel gauge sender 3
G237 item 1.
Move fuel gauge sender 3
G237 to left side.
Press down both retaining clips on retainer for fuel delivery unit (arrows).
Pull fuel delivery unit slightly upwards and at the same time take out fuel gauge sender 3
G237.
Note
Keep in mind that the fuel gauge sender 3
G237 still contains fuel.
Installing
Tightening torques (see the separate procedure)
Pull both retaining clips on retainer upwards (arrows) so that they engage audibly before installing the fuel delivery unit.
Pull fuel delivery unit up slightly and insert fuel gauge sender 3
G237.
Then press fuel delivery unit carefully into retainer so that it engages audibly.
Fit fuel supply line (2) and fuel gauge sender 3
G237 item 1 so that they engage audibly.
Connect electrical connectors
1 ... 3 on underside of flange (left-side).
Vehicles up to approx. 10.2002:
Fit flange with new O-ring into fuel tank; note correct installation position:
The electrical connectors are positioned transversely in relation to direction of travel.
Dimension x (left-side) = dimension x (right-side)
Secure locking ring for flange (left-side) in diagonal sequence (arrows).
Vehicles from approx. 11.2002 onwards:
Install new seal for flange (seal must be installed dry).
Fit flange into fuel tank; note correct installation position:
Lug (2) on flange must be between tabs (1) and (3) on fuel tank.
Tighten locking ring.
All vehicles (continued):
Attach electrical connectors (1) and (2) on flange (left-side).
Secure cover for flange (left-side) (arrows).
Connect battery. Observe notes on procedures required after connecting battery (repair group 27).