Tip & How-To about Audi A4

How to change temperature sender on AUDI 1.9 TDI

The specific location of the sender is on back of cylinder-head near by vacuum-fuel double pump. There is an assurance clip and a rubber sealing O-ring. Heed of antifreeze solution temperature!!!
Before you try to change the sender you must be sure that the sender is out of order. First you must check the thermostat operating. Thermostat checking:
1. Cold engine. Start up the engine and watch of the water temp indicator. After first value 60 Celsius Degree you still warm up the engine until the lifter (pointer) reach 80 C deg. (second mark after 60 C deg.). At this time you let engine running at idle speed and check with your hand the thermostat plastic housing and hose temperature in bottom left side of the engine. Heed of alternator driving belt and ventilator fan !!!
2. If the thermostat is good the hose must be cold until the water temp indicator reach almost 90 C deg.
3. The thermostat opening temperature is 87 C deg.
4. If the hose is already warm the thermostat is out of order.
5. If the thermostat and the temp sender are OK the last piece out of order will be the instrument cluster.

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is there an acsess panel under the back seat for the fuel pump and sending unit
I don't think so according to the literature:
REMOVAL & INSTALLATION CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.
  1. Relieve the fuel system pressure. Refer to procedure in this section.
  2. Disconnect the negative battery cable.
  3. Drain the fuel tank, then remove the fuel tank from the vehicle. Refer to procedure located later in this section.
  4. Thoroughly clean the area surrounding the sender snapring. Compressed air may be directed around the seal. CAUTION
    Safety glasses MUST be worn when using compressed air to avoid eye injury due to flying dirt particles!
  5. While holding the modular fuel sender assembly down, remove the snap-ring from the designated slots located on the retainer. WARNING
    The modular fuel sender assembly may spring up from its position. When removing the modular fuel sender from the tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float.
  6. Remove the external fuel strainer.
  7. Detach the Connector Position Assurance (CPA) piece from the electrical connector and detach the fuel pump electrical connector.
  8. Gently release the tabs on the sides of the fuel sender at the cover assembly. Begin by squeezing the sides of the reservoir and releasing the tab opposite the fuel level sensor. Move clockwise to release the second and third tabs in the same manner.
  9. Lift the cover assembly out far enough to detach the fuel pump electrical connection.
  10. Rotate the fuel pump baffle counterclockwise and remove the baffle and pump assembly from the retainer.
  11. Slide the fuel pump outlet out of slot, then remove the fuel pump outlet seal. To install:
  12. Install the fuel pump outlet seal, then slide the fuel pump outlet in the slots of reservoir cover.
  13. Install the fuel pump and baffle assembly onto the reservoir retainer and rotate clockwise until seated.
  14. Install the lower retainer assembly partially into the reservoir. Line up all 3 sleeve tabs. Press the retainer onto the reservoir making sure all 3 tabs are firmly seated. NOTE: Gently pull on the fuel pump reservoir from retainer to assure a secure fastening. If not secure, replace the entire fuel sender.
  15. Attach the fuel pump connector.
  16. Fasten the CPA connector to the fuel sender cover.
  17. Install a new external fuel strainer.
  18. Install the modular fuel sender.
  19. Install the fuel tank in the vehicle.
  20. Connect the negative battery cable.
  21. Pressurize the fuel system and verify no leaks. Fig. 1: The fuel pump/fuel sender module assembly is mounted in the fuel tank 87955078.gif
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Oct 29, 2010 • 1999 Chevrolet Malibu
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how do I change a fuel pump on a 2002 yukon
Need to know the size of the engine but this is a picture of what it is....


Posting the rest of the directions for you:


1cf4b2b.gif
Illustrating fuel pump and sending unit sensor (3) on 2000-2004 4.8L, 5.3L, 6.0L Engines

Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:
    • Negative battery cable
  3. Relieve the fuel system pressure.
  4. Drain the fuel tank.
  5. Remove or disconnect the following:
    • Fuel tank

    WARNING Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints.

  6. Disconnect the fuel and evaporative emission (EVAP) lines from the fuel tank module.
  • Fuel sender assembly retaining ring using a fuel tank sending unit wrench. Remove the fuel sender assembly and the seal. Discard the seal.
  • Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
  • Fuel pump electrical connector
  • Electrical connector retaining clip from the fuel level sensor
  • Sensor electrical connector from under the fuel sender cover
  • Fuel level sensor retaining clip
  • Squeeze the locking tangs and remove the fuel level sensor.
  • Remove the fuel pressure sensor.
    • To install:
    1. Install or connect the following:
      • Fuel pressure sensor
      • Fuel level sensor
      • Sensor retaining clip
      • Electrical connector to the fuel level sensor
      • Electrical connector retaining clip to the fuel level sensor
      • Fuel pump electrical connector

      NOTE Always install a new fuel strainer when replacing the fuel tank fuel pump module.

      • New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
      • New seal on the fuel tank

      NOTE The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

      • Fuel sender assembly into the fuel tank
      • Fuel sender assembly retaining ring
      • Fuel tank. Install the fuel tank strap attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
    2. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable.
    3. Turn the ignition ON for 2 seconds.
    4. Turn the ignition OFF for 10 seconds.
    5. Turn the ignition ON.
    6. Inspect for fuel leaks.
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    Sep 13, 2010 • 2002 GMC Yukon Denali
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    1answer

    replace fuel pump for 2002 gmc sierra 2500
    First...this is where the pump is (gas tank) on the engines listed:

    6f9f9d7.gif

    Illustrating fuel pump and sending unit sensor (3) on 1999-2005 4.8L, 5.3L, 6.0L Engines


    Removal & Installation
    1. Before servicing the vehicle, refer to the Precautions section.
    2. Remove or disconnect the following:
      • Negative battery cable
    3. Relieve the fuel system pressure.
    4. Drain the fuel tank.
    5. Remove or disconnect the following:
      • Fuel tank
    8e4564e.gif
    WARNING Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

    • Fuel sender assembly retaining ring using a fuel tank sending unit wrench. Remove the fuel sender assembly and the seal. Discard the seal.
  • Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
    • Fuel pump electrical connector
    • Electrical connector retaining clip from the fuel level sensor
    • Sensor electrical connector from under the fuel sender cover
    • Fuel level sensor retaining clip
  • Squeeze the locking tangs and remove the fuel level sensor.
  • Remove the fuel pressure sensor.
    • To install:
    1. Install or connect the following:
      • Fuel pressure sensor
      • Fuel level sensor
      • Sensor retaining clip
      • Electrical connector to the fuel level sensor
      • Electrical connector retaining clip to the fuel level sensor
      • Fuel pump electrical connector
      NOTE Always install a new fuel strainer when replacing the fuel tank fuel pump module.

      • New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
      • New seal on the fuel tank
      NOTE The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

      • Fuel sender assembly into the fuel tank
      • Fuel sender assembly retaining ring
      • Fuel tank. Install the fuel tank strap attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
    2. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable.
    3. Turn the ignition ON for 2 seconds.
    4. Turn the ignition OFF for 10 seconds.
    5. Turn the ignition ON.
    6. Inspect for fuel leaks
    Read full answer
    Oct 25, 2009 • 2002 GMC Sierra 1500
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    1answer

    I need to replace the fuel pump in my 940 Volvo.
    Disconnect battery ground strap before beginning to work on the fuel/electrical system. Do not smoke or have anything in the area which can ignite or cause sparks

    1. Drain enough fuel from tank to prevent spilling, no more than 4 gallons (16 liters) of fuel should remain. Use suitable pumping equipment.
    2. Remove floor mat and panel from trunk.
    1. Disconnect wiring harness connector to sending unit. Remove wires from connector.
    2. Disconnect ground wire to sender. Push wires through grommet.
    3. Remove cover for access to tank sending unit.
    1. All models: Disconnect from the fuel tank sending unit:
      1. Breather hose C
      2. Return hose A
      3. Supply hose B
      4. Filler hose D
      5. Wiring harness from clip E
    1. Clean area and unscrew fuel tank sender/pump cap or equivalent. Remove tank sender/pump and seal.
    2. Remove pump from sender/pump assembly.
    INSTALLATION
    1. Inspect the pump for damage, feed pump hose and wiring for wear. Replace as needed.
    2. Install new pump to sender/pump assembly.
    3. Install rubber seal in neck of tank. Lubricate inside of seal.
    1. Install fuel tank sender/pump unit. Align it with the moulded joint (arrows) on tank.
    2. Apply rustproofing compound to exposed metal portions of tank sender.
    CAUTION : With tape or rubber caps, protect fuel sender openings from overspray.
    1. Torque fuel tank sender/pump lock ring to: 22 ft-lb (30 Nm)
    2. Reassemble components in reverse order. Use tie straps to secure all hoses and wiring.
    Read full answer
    Jun 04, 2009 • 1995 Volvo 940
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    1answer

    water temparature gauge
    The specific location of the sender is on back of cylinder-head near by vacuum-fuel double pump. There is an assurance clip and a rubber sealing O-ring. Heed of antifreeze solution temperature!!!
    Before you try to change the sender you must be sure that the sender is out of order. First you must check the thermostat operating. The thermostat location is on back of alternator at the bottom side of the bracket. IMPORTANT: It is NOT necessary to replace the alternator if you want to change the thermostat !!!
    Thermostat checking:
    1. Cold engine. Start up the engine and watch of the water temp indicator. After first value 60 Celsius Degree you still warm up the engine until the lifter (pointer) reach 80 C deg. (second mark after 60 C deg.). At this time you let engine running at idle speed and check with your hand the thermostat plastic housing and hose temperature in bottom left side of the engine. Heed of alternator driving belt and ventilator fan !!!
    2. If the thermostat is good the hose must be cold until the water temp indicator reach almost 90 C deg.
    3. The thermostat opening temperature is 87 C deg.
    4. If the hose is already warm the thermostat is out of order.
    5. If the thermostat and the temp sender are OK the last piece out of order will be the instrument cluster.



    Read full answer
    Oct 10, 2008 • 2000 Audi A4
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