Removing and installing fuel gauge sender III (-G237) — AUDI

AEB AFY AGA AGE AJG AJK AJL AJP ALF ALG ALT ALW AML AMM AMX ANB ANK APC APR APS APU APZ AQD AQE AQJ ARE ARH ARJ ARK ARN ARS ART ASG ASM ASN ATX AWT AZA BAS BBJ BCY BDV BES
Special tools and workshop equipment required

Wrench 2012 A

Removing

Observe safety precautions=> Page
20-1
.

Observe rules for cleanliness => Page
20-4
.

The fuel tank must not be more than3/4full when removing the fuel gauge sender III. Drain the fuel tank if necessary=>Page
20-119
.

Obtain code on vehicles with coded radio/integrated radio and navigation system.
With ignition switched off disconnect battery earth strap.
Open fuel filler cap briefly, then close it again.
Unbolt cover for flange on fuel tank under floor trim in luggage compartment.

Note:

On Avant models, first remove luggage compartment floor covering

=> General body repairs, Interior; Repair group 70; Trim panels - Avant
General body repairs, Interior
Trim panels - Avant

Carefully release 2-pin connector -arrow- and unplug.

The fuel tank must not be more than 3/4 full when removing fuel gauge sender III.
Remove union nut with wrench 2012 A.
Carefully pull fuel gauge sender III together with seal out of fuel tank opening.

Installing

Install in reverse sequence; note the following points:

Insert fuel gauge sender III -Item -2- into fuel tank as illustrated.
The float -1- points to front left.

Notes:

The arrow points in direction of travel.
The fuel tank is illustrated in part-sectional view.

Vehicles with 4-cylinder and 6-cylinder engine: turn sender clockwise around its own axis while inserting into fuel tank -arrow-.

Note:

Do not bend arm of float on fuel gauge sender when installing.

Sender III is properly inserted if:

Float -1- and arm of float -2- on sender point to front left.

Notes:

The arrow points in direction of travel.
The fuel tank is illustrated in part-sectional view.

Slide new seal for fuel gauge sender III over sender flange.
The seal should be dry when fitting into fuel tank opening.

Check fitting position of fuel gauge sender III:
Marking on sender -2- must coincide with marking on fuel tank -1-.

Notes:

The arrow points in direction of travel.
Do not turn sender anti-clockwise past the marking.

Tighten union nut for fuel gauge sender III to 30 Nm.

Notes:

When the battery is reconnected, re-activate electrical equipment (radio/radio and navigation system, clock, electric windows) as described in the Owner's Manual.
Further procedures after reconnecting the voltage supply:

=> Motronic injection and ignition system; Repair group 24
Motronic injection and ignition system

To finalise procedure:

Fill up tank.
Measure total resistance of fuel gauge senders => Page
20-216
.
Specification: approx 270 ω(tank full)

Tightening torques

Component · Nm
Union nut for fuel gauge sender III · 30
Battery terminal to battery post · 5