Note: When working on fuel system components, observe the precautions given in Chapter 1.
Withdrawal
1. The sensor is mounted on top of the fuel tank and is accessible through a hatch in the trunk floor. The unit provides an AC voltage signal to the fuel level indicator installed in the dashboard, and is also the junction of the supply and return fuel hoses.
2. The unit is immersed in the fuel tank.
3. Make sure that the car is on a level surface, then disconnect the negative cable from the battery and take it away from the terminal.
4. Remove finishing from a floor of a luggage carrier. On Wagon models, fold the rear seat forward, then remove the set of screws holding the mat to the floor. Remove the mat.
5. Turn off screws of fastening of the hatch, lift the hatch from a floor.
6. Disconnect the wiring harness connector from the sensor.
7. Wrap a rag around the fuel hoses to absorb spilled fuel, then loosen the clamps and remove the hoses from the fittings on the gauge. Pay attention to the arrows on the pipes indicating the direction of fuel flow - mark the fuel supply hoses accordingly to ensure correct installation. Also pay attention to the location of the block in the fuel tank.
8. Unscrew the plastic fastening ring and lift the sensor, holding it for a while above the fuel level in the tank until excess fuel drains from it.
9. Remove the sensor, put it on a piece of cardboard or rags. Inspect the float at the end of the arm - replace the sensor if it appears to be damaged.
10. The fuel suction tube in the sensor is spring loaded. Make sure the pickup tube moves freely under spring tension against the sensor body.
11. Remove the rubber seal from the hole in the fuel tank, inspect it and replace if necessary.
12. Inspect the sensor slider and conductor; rinse them from dirt and inspect for conductor breaks. The electrical specification for the sensor is not specified by Audi, but the integrity of the runner and conductor can be checked by connecting a multimeter (in resistance measurement mode) across the sensor connector terminals. The resistance should change as the float arm moves up and down; if there is an open circuit, the sensor is defective and should be replaced.
Installation
13. Install in reverse order, but position sensor housing in fuel tank as noted during removal.
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