MOGolf
Top Post Dawg
- Joined
- Jun 27, 2001
- Location
- underneath something
- TDI
- 2001 Golf GLS TDI Reflex silver, rough road suspension and steel skid plate, 2004 Passat Variant, Candy White, rough road suspension and geared balanced shaft module, and much, much more. 2016 LR RR HSE TD6, 2019 Jaguar I-PACE
I'm posting this in 'General Maintenance' for A4s because it applies whether you've replaced the cluster or not. Those who have replaced their clusters should perform this procedure because your gauge may not be accurate (mine read high and a high reading gauge can lead to running out of fuel when you think you have fuel). If you replace the sender, your gauge may not be accurate.
Do this procedure when the gauge reads 1/4 tank or less, but not down to the red line or below.
Tools: large enough container to hold the siphoned fuel, hammer, screwdriver, Phillips (cross-head) screwdriver, siphon hose/pump, funnel, graduated container for refueling, paper towels/rags/absorbant cloths, VAG-COM or equivalent.
From right side of car:
Lift up rear seat.
Lift up carpet flap.
Place paper towels (or other 'drop cloth' material) between the sender and the door opening.
Remove 3 screws on access panel.
Lay access panel aside.
Disconnect electrical connector and move aside. I hooked it under the 'carpet'.
Push in 'button' on 1 fuel line and gently pull up to release line from sender, but do not fully remove. The 'button' is on the connector end facing away from the fuel lines.
Repeat for the other line.
Let fuel drain until you don't hear fuel draining anymore. For the heaaring impaired wait at least 30 seconds. Proceding with the retaining ring removal should be enough time.
Note position of retaining ring. Perhaps make your own alignment marks so you know when you've got it reinstalled 'just like new'.
Mark where big arrow on sender unit points to edge of opening, but don't scratch the paint. Use a felt marker, piece of tape or other appropriate means.
Take big hammer and screwdriver and whack a rib on the retaining ring to loosen. Repeat as necessary.
Unscrew retaining ring.
Stuff a paper towel around the outside of the retaining ring near the fuel lines.
Lift fuel lines off of sender and move to the side (over the paper towel).
Remove retaining ring.
Lift up sender just a bit and let fuel drain.
Repeat as necessary, tilting slightly towards the back left of vehicle.
When bottom of sender is reachable, you'll see a black part. Push up on the bottom of black part and release. Doing this repeatedly (like pushing an elevator(lift) button ) will aid in draining the fuel from the sender. You'll probably be able to see the level of fuel inside the sender.
When drained sufficiently, lift out sender being mindful of the float mechanism. Don't bend its arm.
Remove the sender from vehicle and place on a clean absorbant cloth covered surface out of the way.
You can place the fuel lines back over the opening if you want to at this point in case there is any fuel that still wants to drip out.
Siphon out fuel into a clean container. I found it useful to lightly clamp my siphon hose to the edge of the opening to keep the end of the hose at the bottom of the tank.
Pour back in 7 liters of fuel. I poured a little bit (400-700 ml) at a time into a Mason jar and poured it into the tank, keeping track of the quantity until 7 liters were in the tank.
Move fuel lines aside (if necessary), install sender unit (aligning mark and arrow) and retaining ring (tightening to the point it was before disassembly).
Connect electrical connector and fuel lines.
Do not sit in the car, but put key in starter switch, turn to power on (but don't start the car) and connect/startup VAG-COM (or equivalent).
Go to the instrument controller adaptation group 030.
If the fuel gauge needle does not settle pointing to the red mark on the gauge, adjust the number shown in VAG-COM to calibrate the gauge. A higher number increases the fuel indication; a lower number decreases the fuel indication.
When satisfied, close VAG-COM, remove the key and complete reassembly of the car. We waited until now to put the access cover back on just in case you skipped the step of reconnecting the electrical connector. This would be obvious when the gauge didn't read correctly.
Return the remaining fuel to the car's fuel tank via the normal filling orifice. This is where you may need the funnel.
Safely dispose of fuel soaked cloths.
Do this procedure when the gauge reads 1/4 tank or less, but not down to the red line or below.
Tools: large enough container to hold the siphoned fuel, hammer, screwdriver, Phillips (cross-head) screwdriver, siphon hose/pump, funnel, graduated container for refueling, paper towels/rags/absorbant cloths, VAG-COM or equivalent.
From right side of car:
Lift up rear seat.
Lift up carpet flap.
Place paper towels (or other 'drop cloth' material) between the sender and the door opening.
Remove 3 screws on access panel.
Lay access panel aside.
Disconnect electrical connector and move aside. I hooked it under the 'carpet'.
Push in 'button' on 1 fuel line and gently pull up to release line from sender, but do not fully remove. The 'button' is on the connector end facing away from the fuel lines.
Repeat for the other line.
Let fuel drain until you don't hear fuel draining anymore. For the heaaring impaired wait at least 30 seconds. Proceding with the retaining ring removal should be enough time.
Note position of retaining ring. Perhaps make your own alignment marks so you know when you've got it reinstalled 'just like new'.
Mark where big arrow on sender unit points to edge of opening, but don't scratch the paint. Use a felt marker, piece of tape or other appropriate means.
Take big hammer and screwdriver and whack a rib on the retaining ring to loosen. Repeat as necessary.
Unscrew retaining ring.
Stuff a paper towel around the outside of the retaining ring near the fuel lines.
Lift fuel lines off of sender and move to the side (over the paper towel).
Remove retaining ring.
Lift up sender just a bit and let fuel drain.
Repeat as necessary, tilting slightly towards the back left of vehicle.
When bottom of sender is reachable, you'll see a black part. Push up on the bottom of black part and release. Doing this repeatedly (like pushing an elevator(lift) button ) will aid in draining the fuel from the sender. You'll probably be able to see the level of fuel inside the sender.
When drained sufficiently, lift out sender being mindful of the float mechanism. Don't bend its arm.
Remove the sender from vehicle and place on a clean absorbant cloth covered surface out of the way.
You can place the fuel lines back over the opening if you want to at this point in case there is any fuel that still wants to drip out.
Siphon out fuel into a clean container. I found it useful to lightly clamp my siphon hose to the edge of the opening to keep the end of the hose at the bottom of the tank.
Pour back in 7 liters of fuel. I poured a little bit (400-700 ml) at a time into a Mason jar and poured it into the tank, keeping track of the quantity until 7 liters were in the tank.
Move fuel lines aside (if necessary), install sender unit (aligning mark and arrow) and retaining ring (tightening to the point it was before disassembly).
Connect electrical connector and fuel lines.
Do not sit in the car, but put key in starter switch, turn to power on (but don't start the car) and connect/startup VAG-COM (or equivalent).
Go to the instrument controller adaptation group 030.
If the fuel gauge needle does not settle pointing to the red mark on the gauge, adjust the number shown in VAG-COM to calibrate the gauge. A higher number increases the fuel indication; a lower number decreases the fuel indication.
When satisfied, close VAG-COM, remove the key and complete reassembly of the car. We waited until now to put the access cover back on just in case you skipped the step of reconnecting the electrical connector. This would be obvious when the gauge didn't read correctly.
Return the remaining fuel to the car's fuel tank via the normal filling orifice. This is where you may need the funnel.
Safely dispose of fuel soaked cloths.