Table of contents: Removal ↓ Installation ↓
Application: Before starting work, read the warnings contained in paragraph 1.
Removal
1. The sensor is installed in the fuel tank. Access to it is possible through the hatch in the butt of the luggage compartment. Removal implies contact of the tank contents with the atmosphere - take special fire safety measures. The surrounding space around the car should be well ventilated so that fuel vapors do not accumulate. If possible, remove the sensor unit with the tank as empty as possible or pump out the fuel into a suitable canister.
2. Position the vehicle horizontally. Disconnect the ground cable from the battery as described in chapter 5A.
3. As described in chapter 11, remove the trim from the luggage compartment floor.
4. Loosen the screws securing the hatch and remove it from the floor.
5. Disconnect the electrical connector from the sensor unit (Fig. 4.5).
6. Place a rag under the hoses to collect the fuel. Loosen the clamps and remove the feed and return hoses (fig. 4.6.a, b). Hang tags on the hoses to avoid confusion during installation. Release the tubes from the fasteners on the support ring.
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7. Remember the direction of the arrows and the ring, unscrew the plastic ring of the block attachment in the tank. Audi/VAG mechanics have special tools for this operation. However, to do this, just insert two screwdrivers into the slots of the ring and cross them. You can use a large adjustable wrench "dog" (fig. 4.7, a-c).
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8. Carefully remove the sensor assembly and seal from the opening in the tank.
9. Inspect the sensor float - there should be no holes in it and there should be no fuel gurgling in it. Replace a damaged float. A damaged seal of the hole in the tank should also be replaced. Inspect the runner and rheostat of the sensor - there should be no breaks in the conductor. Remove any possible dirt from the rheostat.
Installation
10. Insert the sensor unit into the fuel tank together with the new seal. The seal must be dry during installation.
11. Align the line on the sensor with the arrow on the fuel tank, install the support ring and tighten (Fig. 4.11). To ensure that the arrows align when tightening the ring, turn the flange slightly counterclockwise while tightening the ring.
12. Connect the fuel hoses and tighten the clamps.
13. Connect the wiring connector to the pump/sensor unit.
14. Install the hatch and tighten the screws that secure it.
15. Install the trim on the luggage compartment floor.
16. Connect the battery as described in chapter 5A.