The support housing photographed here is usually glued into the fuel tank; but here it is shown separately for the sake of clarity. Dismantling the fuel level sensor (1) possible after pressing the key (arrow). Pressing the key unlocks (2). You can remove the fuel level sensor.
Here you can see the blank flange of the fuel tank under the bottom of the trunk.
The numbers indicate:
- 1 - return fuel line from the injection system;
- 2 - connector for fuel pump and fuel level sensor;
- 3 - fuel supply line to the injection system.
The locking ring of the fuel level sensor is unscrewed here with a special tool (2) with a ratchet (1).
Mounting position of blind flange: arrow on flange (1 or 2) must be opposite the mark on the fuel tank (3). In vehicles with front-wheel drive and all-wheel drive, there is a corresponding arrow in each case.
The sensor is inserted from above into the intake manifold housing inside in the middle of the fuel tank. You will find how it works in the chapter Tools and devices.
Due to the different shape of the fuel tanks, there are also different fuel level sensors for front-wheel drive and all-wheel drive models. Identifier: Rectangular float fuel gauge for front wheel drive models; fuel level sensor for quattro - with spherical float.
Dismantling the fuel level sensor
Important: the fuel tank can only be filled to a maximum of 2/3, otherwise fuel will leak out!
1. Fold down the boot floor.
2. Unscrew the black metal cover.
3. Mark the fuel supply and return fuel lines - the arrows on the fuel pipes indicate the direction of flow.
4. Remove both fuel lines after opening the clamps.
5. Unscrew the plastic union nuts. Most often they sit very firmly. Therefore, place, if possible, a blunt screwdriver on the edge of the nut and loosen the nut with light hammer blows on the screwdriver handle. If necessary, install it on different edges of the nut.
6. Now you can slightly pull up the blind flange of the fuel tank.
7. If necessary, dismantle the fuel return line and electric wire on the reverse side of the blind flange.
8. Mark the mounting position of the hose and wire for reassembly.
9. Now grasp the fuel tank with your hand and remove the sensor while pressing the mounting tab out of the intake manifold housing.
10. Disconnect the fuel level sensor connector on the blind flange.
11. Before assembly, moisten the O-ring of the blind flange with gasoline.
12. Mounting position of the blind flange: the arrow on the flange must be opposite the mark on the fuel tank. Front wheel drive and all wheel drive vehicles have their own arrow for each case.
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