Removing and installing fuel gauge sender 3 G237 (up to model year 2013) — AUDI

Removing and installing
fuel gauge sender 3
G237
(up to model year 2013)
Special tools and workshop equipment required
Electric cutter
V.A.G 1561A
Blade (L-shaped, 25.4 mm)
V.A.G 1561/22
Wrench
T10202
Adhesive sealant
Electronic parts catalogue
Removing
Observe safety precautions
Chapter
.
Observe rules for cleanliness
Chapter
.
WARNING
Danger! Fuel may escape.
The fuel tank must not be more than
3
/
4
full when removing the fuel gauge sender, otherwise a large amount of fuel will escape.
Drain fuel tank if necessary
Chapter
.
Caution
To prevent irreparable damage to the electronic components when disconnecting the battery:
Observe notes on procedure for disconnecting the battery.
Disconnect earth wire
2
from battery terminal
Electrical system
Rep. gr.
27
Battery, Disconnecting and connecting battery
.
Remove luggage compartment back panel trim
General body repairs, interior
Rep. gr.
70
Luggage compartment trim panels; Overview of fitting locations - luggage compartment trim panels
.
Vehicles with high-voltage system:
DANGER!
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock.
The high-voltage system may only be de-energised by a suitably qualified person (Audi high-voltage technician).
It must be definitely confirmed that the high-voltage system is de-energised. The system may only be de-energised using the
vehicle diagnostic tester
via
“Guided Fault Finding”
.
The qualified person (Audi high-voltage technician) confirms that the system is de-energised and uses the
locking cap
T40262
to ensure that the system cannot be re-energised. The ignition key and the
maintenance connector for high-voltage system
TW
are then stored in a safe place by the qualified person.
The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs.
Note
De-energising high-voltage system:
Connect vehicle diagnostic tester
Select
Guided Fault Finding
mode
Using the
Go To
button, select the following menu options in succession:
Selecting function/component
Body
Electrical system
Self-diagnosis compatible systems
8C - Hybrid battery management -J840
8C - Hybrid battery management, functions
51 - De-energise high-voltage system (Rep. gr. 93)
The system must first be de-energised by an Audi high-voltage technician before any work is performed on the high-voltage system
Electrical system, hybrid
Rep. gr.
93
De-energising high-voltage system
.
The types of work for which the high-voltage system has to be de-energised are indicated in the instructions for the procedure. For further information, see
Electrical system, hybrid
Rep. gr.
93
General warning instructions for work on the high-voltage system
.
Note
The high-voltage system must be de-energised before beginning any work on components of hybrid vehicles that are connected to the high-voltage system (e.g. electrically driven air conditioner compressor).
For certain work on hybrid vehicle components that are installed near high-voltage system components, the high-voltage system must be de-energised prior to beginning work
Electrical system, hybrid
Rep. gr.
93
De-energising high-voltage system
.
Remove
drive battery
A2
Electrical system, hybrid
Rep. gr.
93
High-voltage battery unit; Removing and installing high-voltage battery
.
All vehicles (continued):
If fitted, remove infotainment control units and brackets (left-side)
Communication
Rep. gr.
91
Infotainment system; Overview of fitting locations - infotainment system
.
Remove storage compartment (rear)
General body repairs, interior
Rep. gr.
72
Rear seats; Exploded view - rear seat backrest
.
Fold insulating mat to one side in vicinity of cover for flange (at front of luggage compartment).
Use
electric cutter
V.A.G 1561A
and
blade (L-shaped, 25.4 mm)
V.A.G 1561/22
to cut through adhesive sealant around cover for flange.
Detach cover for flange.
Repair painted surfaces
Paintwork manual
.
Apply anti-corrosion coating as necessary
Surface treatment/chemical materials
.
Press release tab and disconnect breather line
1
.
WARNING
Danger! Fuel may escape.
The fuel tank must not be more than
3
/
4
full when removing the fuel gauge sender, otherwise a large amount of fuel will escape.
Remove locking ring using
wrench
T10202
.
Pull flange
3
out of opening in fuel tank.
Press release tab and disconnect breather line
2
.
Take seal
1
out of opening in fuel tank.
Release retainer catch and unplug electrical connector on
fuel gauge sender 3
G237
.
Carefully take flange with
fuel gauge sender 3
G237
item 4
out of opening in fuel tank.
Note
When removing, make sure you do not bend float arm of fuel gauge sender.
Installing
Installation is carried out in the reverse order; note the following:
Note
Renew seal.
When inserting, make sure you do not bend float arm of fuel gauge sender.
Carefully insert flange with
fuel gauge sender 3
G237
item 4
into fuel tank.
Plug in electrical connector and make sure it is correctly engaged.
Connect breather line
2
so it engages audibly.
Install new seal
1
for flange (seal must be installed dry).
Fit flange
3
into fuel tank.
Fit flange in correct installation position.
Caution
Leakage risk
The seal must not be pinched or damaged when installing the flange.
Lug
2
on flange must be between tabs
1
and
3
on fuel tank.
Arrow on flange points in direction of travel.
Connect breather line so it engages audibly.
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.
Caution
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.
Dimension
a
= 7 mm
Apply new sealant bead onto trimmed-down adhesive sealant on cover for flange and fit cover.
Two holes on cover face towards rear of vehicle.
Install storage compartment (rear)
General body repairs, interior
Rep. gr.
72
Rear seats; Exploded view - rear seat backrest
.
Install brackets and control units for infotainment system
Communication
Rep. gr.
91
Infotainment system; Overview of fitting locations - infotainment system
.
Install luggage compartment back panel trim
General body repairs, interior
Rep. gr.
70
Luggage compartment trim panels; Overview of fitting locations - luggage compartment trim panels
.
Observe steps required after re-connecting battery
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Vehicles with high-voltage system:
Install
drive battery
A2
Electrical system, hybrid
Rep. gr.
93
High-voltage battery unit; Removing and installing high-voltage battery
.
DANGER!
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock.
The high-voltage system may only be re-energised by a suitably qualified person (Audi high-voltage technician).
The system may only be re-energised using the
vehicle diagnostic tester
via
“Guided Fault Finding”
.
The vehicle is then made ready for operation again by the qualified person (Audi high-voltage technician).
The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs.
Note
Re-energising high-voltage system:
Connect vehicle diagnostic tester
Select
Guided Fault Finding
mode
Using the
Go To
button, select the following menu options in succession:
Selecting function/component
Body
Electrical system
Self-diagnosis compatible systems
8C - Hybrid battery management -J840
8C - Hybrid battery management, functions
51 - Re-energise high-voltage system (Rep. gr. 93)
Tightening torques
Chapter
“
Exploded view - fuel delivery unit/fuel gauge senders
”