Application: Before starting work, read the warnings contained in paragraph 1.
Withdrawal
1. The sensor is installed in the fuel tank. Access to it is possible through the hatch in the ass of the luggage compartment. Removal involves exposing the contents of the tank to the atmosphere - take special fire precautions. The surrounding area around the vehicle must 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 the fuel into a suitable container.
2. Install the car horizontally. Disconnect the wire "masses" battery as described in chapter 5A.
3. As described in chapter 11, remove the trim from the luggage compartment floor.
4. Turn away screws of fastening of the hatch and remove it from a floor.
5. Disconnect the electrical connector from the sensor block (pic. 4.5).
6. Lay a rag under the fuel collection hoses. Loosen the clamps and remove the supply and return hoses (pic. 4.6.a, b). Place tags on the hoses to avoid confusion during installation. Release the tubes from the fasteners on the support ring.
7. Remember the direction of the arrows and rings, unscrew the plastic ring securing the block in the tank. Audi/VAG mechanics have a special tool for this operation. However, for this it is enough to insert two screwdrivers into the slots of the ring and cross them. You can use a large wrench "dog" (pic. 4.7, a-c).
8. Carefully remove the sensor assembly and seal from the tank opening.
9. Inspect the sensor float - there should be no holes in it and no fuel should gurgle in it. Replace damaged float. A damaged seal in the tank opening must also be replaced. Inspect the slider and sensor rheostat - there should be no breaks in the conductor. Remove any possible dirt from the rheostat.
Installation
10. Insert sensor assembly into fuel tank with new seal. Seal must be dry when installed.
11. Align the line on the sensor with the arrow on the fuel tank, install the support ring and tighten (pic. 4.11). To ensure that the arrows line up when tightening the ring, turn the flange slightly counterclockwise while tightening the ring.
12. Attach fuel hoses and tighten collars.
13. Connect the wiring connector to the pump/sensor assembly.
14. Install the hatch and tighten the screws to secure it.
15. Establish an overlay on a floor of a luggage space.
16. Connect the battery as described in chapter 5A.
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