Overview - Fuel Delivery Unit/Fuel Level Sensor

Fuel Delivery Unit 

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

Courtesy of AUDI OF AMERICA, LLC

1. Suction Jet Pump
   • Clipped to the baffle housing
   • Do not kink
   • To disconnect, press release button on the connection piece.
2. 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
   • Checking holding pressure, refer to TRANSFER FUEL PUMP -G6-, CHECKING .
3. Fuel Line
   • To fuel filter
   • Do not kink
   • To disconnect, press release button on the connection piece.
   • Clipped to the baffle housing
4. Seal
   • Replace
   • Install dry
5. Sealing Flange
   • Removing and installing, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .
6. Locking Ring
   • 120 Nm
   • Loosen and tighten using the Wrench - Fuel Sending Unit T10202
7. Fuel Line
   • Only vehicles with a parking heater: to the parking heater metering pump
   • Do not kink
   • Clipped on the bracket -9-
   • Press the release button to remove from the sealing flange
8. Connector
   • For the Fuel Pump Control Module -J538-
9. Bracket
   • For the connectors
10. Fuel Pump Control Module -J538-
    • Removing and installing, refer to FUEL PUMP CONTROL MODULE -J538-, REMOVING AND INSTALLING .
11. Nut
    • 1.6 Nm
12. Connectors
    • For the Transfer Fuel Pump -G6- and the Fuel Level Sensor -G-
13. Fuel Line
    • To the engine
    • Do not kink
    • Press the release button to remove from the sealing flange
    • Clipped to the fuel tank
14. Fuel Line
    • To the baffle housing distributor
    • Do not kink
    • To disconnect, press release button on the connection piece.
15. Fuel Pressure Regulator
    • Clipped to the baffle housing
    • Removing and installing, refer to FUEL PRESSURE REGULATOR, REMOVING AND INSTALLING .
16. Right Cover
    • For baffle housing
    • Clipped to the baffle housing
    • Removing and installing, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .
17. Left Cover
    • For baffle housing
    • Clipped to the baffle housing
    • Removing and installing, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .
18. Baffle Housing
    • Welded to the fuel tank

Fig 2: Identifying Locking Flange Cover & Bolts -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts -arrows- on the cover -1- to 1.5 Nm.

Fuel Level Sensor 

Fig 3: Identifying Fuel Level Sensor Components

Courtesy of AUDI OF AMERICA, LLC

1. Baffle Housing
   • Welded to the fuel tank
2. Fuel Level Sensor -G-
   • Clipped to the baffle housing
   • For checking the resistance values, refer to FUEL LEVEL SENSOR -G-, CHECKING .
   • Removing and installing, refer to FUEL LEVEL SENSOR -G-, REMOVING AND INSTALLING .
3. Seal
   • Replace
   • Install dry
4. Sealing Flange
5. Locking Ring
   • 120 Nm
   • Loosen and tighten using the Wrench - Fuel Sending Unit T10202
6. Connector
   • For Fuel Level Sensor -G-
7. Connector
   • For Fuel Level Sensor 3 -G237-
   • Inside the fuel tank
   • Attached to the suction line with cable ties
8. Locking Ring
   • 120 Nm
   • Loosen and tighten using the Wrench - Fuel Sending Unit T10202
9. Sealing Flange
   • There are different versions.
   • With Fuel Level Sensor 3 -G237- -11-
10. Seal
    • Replace
    • Install dry
11. Fuel Level Sensor 3 -G237-
    • For checking the resistance values, refer to FUEL LEVEL SENSOR 3 -G237-, CHECKING .
    • Removing and installing, refer to FUEL LEVEL SENSOR 3 -G237-, REMOVING AND INSTALLING .
12. Connector
    • For Fuel Level Sensor 2 -G169- and Fuel Level Sensor 3 -G237-
13. Locking Ring
    • 120 Nm
    • Loosen and tighten using the Wrench - Fuel Sending Unit T10202
14. Sealing Flange
15. Seal
    • Replace
    • Install dry
16. 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 .
17. Mount
    • Welded to the fuel tank