Fuel Level Indicator Issue and Sender Removal

[Mech_Mike412]

So I'm having a problem with my fuel level indications on my S-Line. My fuel gauge keeps hovering around the full mark or jumping around everywhere in between full and 3/4 tank. The range indicator on the info screen is doing the same thing, directly related to the level indicator. I'm pretty sure it's the sending unit under the rear seat (if it's something else, I'd appreciate any input).
I already pulled the rear seat out to try and just inspect the sending unit, but I can't get the retaining ring off. I also prefer to not spend $65 on the special tool for the retaining ring, nor the $200 for an OEM sending unit. Any help will be much appreciated


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[djhemmen]

When I replaced my pump/sending unit I just used a flat blade screwdriver and pounded it with a rubber mallet to remove the retaining ring. What have you tried using for removal?

[Mech_Mike412]

I used a flat screwdriver but I didn't use any mallets or hammers. The sucker didn't even budge.

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[djhemmen]

Your picture looks like there is a bit of rust on the ring so it is probably on there pretty good. I'd say take the screwdriver and give it a few good hits with a hammer/mallet to remove the ring counter clockwise and it should come off.

[Mech_Mike412]

The only reason I didn't do that was because I didn't want to break something haha

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[canadianA4B7]

Spray it with cleaner big time. Let it sit so wd-40 penetrates the rust. It will come off. When i put mine back in I used anti sieze on the mating surfaces and last week I hit it about 3-5x with moderate pressure turned out without a problem.

[adam044]

When I replaced my pump/sending unit I just used a flat blade screwdriver and pounded it with a rubber mallet to remove the retaining ring. What have you tried using for removal?

This what I did when I replaced it in my B5 so I'd probably do the same with the B7.

Definitely sounds like the sender until is bad. I'd honestly just get a new OEM one because it's probably not something you want to replace again. Or just live with it. I delt with mine for a little.

I know with the B5's you could try and clean the contacts on the sender, I'm not sure about the B7s. But I had cleaned my contacts and that only last about a week. Then I had to pull it again.

[Mech_Mike412]

I'm gonna inspect it first to see if I can repair it, more than likely I'll have to buy a new unit though.

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[klrider44]

I'm having a similar problem with mine. My low fuel light is always on and my gauge reads just below half all the time. What is responsible for this issue is it a sensor on the lpfp or is there a separate sensor?


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[Okedokey]

Klrider, I had the same issue, the instrument cluster was coded wrong - coded for Quattro and mine is fwd. changed the code and fixed it instantly.

[klrider44]

Hmmm I have never messed with my cluster before though...


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[Theiceman]

its the sender. as stated find a good size flat blade screwdriver and hit the ring counter clockwise with a hammer on the screwdriver. all of ten seconds. Its quite robust. Replace the seal when you put it back or it might leak gas and vapors.

On mine the pickup line that is clicked into the bottom of the sender had come off and was interfering with the sender.

[klrider44]

When you say sender, which one are you referring to? Because aren't there 2. This is where I get lost. Isn't there one on the pump and a separate fuel level sensor on the other side? I haven't had the chance remove anything from my car yet but I don't understand what is responsible for the reading on the cluster? For instance in the following post the part replaced is obviously not the pump.
http://www.audizine.com/forum/showth...er-Replacement


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[Mech_Mike412]

When you say sender, which one are you referring to? Because aren't there 2. This is where I get lost. Isn't there one on the pump and a separate fuel level sensor on the other side? I haven't had the chance remove anything from my car yet but I don't understand what is responsible for the reading on the cluster? For instance in the following post the part replaced is obviously not the pump.
http://www.audizine.com/forum/showth...er-Replacement


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Well I have a Quattro, not sure how much different it is from the FWD model. A friend of mine told me to unplug one of the sensors and drive around and observe the changes, and do it for both sides

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[adam044]

Hmmm I have never messed with my cluster before though...


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I assume it's probably something you do via VAG COM

[Okedokey]

Yes, you go into vagcom, instrument cluster, coding and make sure the code is correct for your vehicle. Mine had somehow changed and I fixed it and the fuel gauge immediately moved to the correct position. This was after replacing the LPFP and module. This didn't fix it, but the coding did. The symptoms were exactly the same as klridder44's though.

[klrider44]

That is strange what was the code that you changed. I have access to vagcom, but I'm not extremely familiar with the program.


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[wriscolf]

Yes, you go into vagcom, instrument cluster, coding and make sure the code is correct for your vehicle. Mine had somehow changed and I fixed it and the fuel gauge immediately moved to the correct position. This was after replacing the LPFP and module. This didn't fix it, but the coding did. The symptoms were exactly the same as klridder44's though.

That is strange what was the code that you changed. I have access to vagcom, but I'm not extremely familiar with the program.


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Do you guys have starting issues? when i fill up the tank, it is always below the line. Never really "full". My previous cars always went over. I just thought the under F line was a Audi thing.

[Okedokey]

Instrument cluster, coding, follow the help bubble and re-code. Write down what it originally was first ;) so you can go back if needed.

[Mech_Mike412]

So I'm back at this again today. What way method could I use to check each sender unit without removing?

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