Fuel Supply Sensor 3 -G237-, Removing and Installing (AWD)

Fuel Supply Sensor 3 -G237-, Removing And Installing

Special tools, test equipment and auxiliary items







- 2012 A Wrench

Removing
- For removing the filler neck with expansion tank, the fuel tank should not be over 1/4 full. If necessary, empty fuel tank.

CAUTION: After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar(R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

- Vehicles with coded radio/navigation system (RNS) coding, refer to the Owner's Manual if necessary.

Audi A6:

CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.







- Remove cover above battery -arrows-.

NOTE: On vehicles without battery cover: Remove plenum cover.







- Disconnect battery Ground (GND) strap -arrow-, with ignition switched off.

Audi RS6:
- Switch off ignition and remove ignition key.







- Turn locks -arrow- counterclockwise and remove cover -1-
- Remove cover -1- off upward.







- Connect the ground wire to battery -arrow-.

All:
- Briefly open and close fuel tank cap.

Limo:
- Remove cover for sender for fuel gauge located under liner in luggage compartment.

Avant:
- Remove cover for sender for fuel gauge located under liner in luggage compartment.

All:
- If necessary; fold the left or right rear seat back forward.







- Remove cover -arrow- for fuel tank sender.

WARNING: When removing fuel supply sensor 3 the fuel tank should only be 3/4 full. Drain fuel tank if necessary.

NOTE: On Avant models remove luggage compartment lining.







- Carefully disengage 2-pin harness connector -arrow- and disconnect.

WARNING: When removing fuel supply sensor 3 the fuel tank should only be 3/4 full. Otherwise large quantities of fuel escape.







- Remove union nut using 2012 wrench.
- Pull fuel supply sensor 3 from opening in tank.

Installing
Installation is the reverse of removal, however note the following:







- Insert fuel supply sensor 3 Fig. 2 into fuel tank as shown in illustration.
- The float -1- shows to top left.

NOTE:
- The -arrow- shows toward front.
- The fuel tank is shown in a partial side view.







- Vehicles with 6 cylinder engine: While inserting turn sensor clockwise on own axle -arrow-.

NOTE: Do not bend float arm of sensor.

Illustration shows fuel supply sensor 3 correct installed:







- Float -1- and arm -2- of sensor shows to front left.


NOTE:
- -Arrow- shows in driving direction.
- The fuel tank is shown in a partial side view.

- Push new seal for fuel supply sensor 3 over closing flange of sensor.
- Insert seal dry into opening of fuel tank.







- Note the installation position of fuel supply sensor 3.
- Marking -2- on fuel supply sensor 3 must align with marking -1- on the fuel tank.


NOTE: -Arrow- shows in driving direction.







- Tighten union nut for fuel supply sensor 3.
Tightening torque: 30 Nm (22 ft lb).


NOTE: With Battery re-connected, remember to activate electrical equipment (radio, clock, window switches) according to operating instructions.

- Generate readiness code.

Finishing steps:
- Fill vehicle with fuel.
- Check entire resistance of fuel supply sensor 3
- Specification: approximately 270 Ohm (Tank full)

Tightening torque

Torque Nm
Closing ring for fuel pump delivery module 120 Nm (89 ft lb)
Battery connections 5 Nm (44 in. lb).