Attachment Bulletin # 200402
Group: 20Number: 04-02
Date: July 6, 2004
Subject:
Fuel Gauge Diagnosis
Model(s):
See Table 2002 > 2004
Supersedes T.B. Group 20 number 04-01 dated June 17, 2004 due to additional service procedure information.
Condition
Fuel gauge does not read full when tank is full of fuel, fuel gauge inaccurate.
Production
Affects vehicles built up to VINs shown.
Service
CAUTION!
Part numbers listed in this bulletin are for reference only. Always check with your Parts Dept. for the latest parts information.
WARNING!
Prior to working with any fuel system component:
ALWAYS review and heed CAUTIONS AND WARNINGS listed in the Repair Manual sections!
Inspection
- Remove rear seat bottom.
- Remove driver's side fuel sender cover -arrow-.
- Check production date -arrow-on fuel level sender production sticker.
If production date is 312/03 or later (312th day of the year and 03 for 2003):
- No Action Required. Do not complete this Technical Bulletin.
If production date is 311/03 or before (311th day of the year and 03 for 2003):
- Replace Fuel level sender. Proceed to "Fuel Level Sender 2 -G169- Removal".
Fuel Level Sender 2 -G169- Removal
WARNING!
Fuel level sender 2 flange must only be removed with the fuel tank not more than 1/4 full otherwise a great amount of fuel flows out.
If fuel tank is more than 1/4 full:
- Drain fuel tank as necessary (see Repair Manual Fuel supply system, Repair Group 20 - Fuel Supply Fuel supply system (All-wheel drive) "Fuel tank, draining").
^ With fuel tank drained to appropriate level.
^ With ignition switched OFF.
On models with Telematics, Switch off emergency battery. See Repair Manual Repair Group 91, Emergency battery; switching off/on.
- Disconnect battery (see Repair Manual Electrical equipment, Repair Group 27 - Battery, Starter, Generator, Cruise control, "Battery, removing and installing").
- Remove fuel filler cap briefly to relieve pressure in fuel tank, then reinstall cap.
- Remove Fuel Level Sender 2 -G169- from tank and disconnect completely (see Repair Manual Fuel supply system, Repair Group 20 - Fuel Supply Fuel supply system (All-wheel drive) "Fuel gauge sender 2 -G169-, removing and installing").
Fuel Siphoning Hose, Rerouting (2002 A4 Avant & Sedan Quattro's built prior to 8E_2A298311 only)
All vehicles except those listed above, proceed to "Fuel Level Sender 2 -G169- Installing".
^ With Fuel Level Sender 2 -G169- removed from tank:
- Position white siphon hose behind black siphon hose (towards rear of vehicle as shown in cut-away).
- Add an additional tie wrap Part No: N 020 902 2 (white arrow) to the fuel siphon hose assembly, approx. four inches (10 cm) from existing tie wrap (black arrow) towards the center of vehicle.
Note:
Part No: N 020 902 2 is a special fuel resistant wrap tie and is the only part approved for this use.
- Install tie wrap loosely over hoses in visible opening of tank first.
- Hold a small flexible scale along hoses with four inch mark lined up with existing tie wrap as shown, then slide newly installed tie wrap towards center of tank to end of scale.
- Hold in position and pull tie wrap to tighten (snug only, DO NOT collapse white siphon hose!).
- Cut excess off end of tie wrap and discard.
Fuel Level Sender 2 -G169- Installing
- Install new fuel level sender seal.
^ Install seal dry (do not lubricate) into fuel tank opening.
- Install new Fuel Level Sender 2 -G169- (Part No. 8E0 201 317N).
^ Observe installation position of flange lug -2- must be between tabs -1- and -3-on fuel tank (see illustration).
- Tighten locking ring using wrench for fuel tank sender unit 3087.
^ Torque = 145 Nm (106 ft. lbs.)
- Reconnect fuel line and electrical connector on top of Fuel Level Sender 2 -G169- and reinstall sender cover.
- Reconnect battery (observe safety precautions see Repair Manual, Electrical Equipment, Repair Group 27).
- After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual.
- Replace fuel removed from fuel tank.
When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table shown.