Overview - Fuel Delivery Unit/Fuel Level Sensor

Fig 1: Overview Of Fuel Delivery Unit/Fuel Level Sensor

Courtesy of AUDI OF AMERICA, LLC

1. Fuel Level Sensor -G-
   • For checking the resistance values, refer to Fuel Level Sensor -G-, CHECKING .
   • Removing and installing, refer to Fuel Level Sensor -G-, REMOVING AND INSTALLING .
2. Locking Flange
   • Removing and installing, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .
3. Seal
   • Replacing
   • Install dry
4. Locking Ring
   • 110 Nm
   • Loosen and tighten using the Wrench - Fuel Sending UnitT10202
5. Connector
   • For Fuel Level Sensor -G- and Fuel Level Sensor 2 -G169-
6. Connector
   • For Transfer Fuel Pump -G6-
7. Connector
   • For the Fuel Pump Control Module -J538-
8. Fuel Pump Control Module -J538-
   • Removing and installing, refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING .
   • Checking in Guided Functions  , refer to Vehicle Diagnostic Tester
9. Bolt
   • 1.6 Nm
10. Fuel Line to Parking Heater Metering Pump
    • Equipment levels
    • Do not kink
    • Clipped to the fuel tank
    • Connector coupling, separating and connecting, refer to CONNECTOR COUPLINGS, SEPARATING .
11. Fuel Return Line
    • From engine
    • Do not kink
    • Note direction of arrow (fuel supply or return) on locking flange when installing
    • Clipped to the fuel tank
    • Connector coupling, separating and connecting, refer to CONNECTOR COUPLINGS, SEPARATING .
12. Fuel Supply Line
    • To fuel filter
    • Do not kink
    • Note direction of arrow (fuel supply or return) on locking flange when installing
    • Clipped to the fuel tank
    • Connector coupling, separating and connecting, refer to CONNECTOR COUPLINGS, SEPARATING .
13. Locking Ring
    • 110 Nm
    • Loosen and tighten using the Wrench - Fuel Sending UnitT10202
14. Locking Flange
    • Removing and installing, refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING .
15. Seal
    • Replacing
    • Install dry
16. Bracket
    • for Fuel Level Sensor 2 -G169-
17. Fuel Level Sensor 2 -G169-
    • For checking the resistance values, refer to Fuel Level Sensor 2 -G169-, CHECKING .
    • Removing and installing, refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING .
18. Wire
    • For Fuel Level Sensor 2 -G169-
    • Inside the fuel tank
    • Disconnect both lines and connectors as close as possible at the last attachment to replace the electric wire. Route the new line parallel to the old one. The old line remains inside the fuel tank.
19. Mount
    • Welded to the fuel tank
20. Fuel Delivery Unit
    • With Transfer Fuel Pump -G6-
    • Check the electric fuel pump in Guided Fault Finding  using the Vehicle Diagnostic Tester.
    • Removing and installing, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .
    • Fill the fuel tank with at least five liters of fuel after installing

Fig 2: Identifying Cover Bolts For Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the cover screws -arrows- to 1.5 Nm.