Fuel tank and fuel pump

Removing the fuel sender

~1min read

Important: the fuel tank must be filled to a maximum of 2/3, otherwise fuel will spill!

PROCEDURE

Fold the luggage compartment mat aside.

Unscrew the black protective cap.

Disconnect the multi-pin connector.

Squeeze the retaining clips on the return fuel line connector and remove the fuel line.

Unscrew the fuel supply line.

Unscrew the plastic union nut. It is often very tight. Place a blunt screwdriver against one of the flats of the nut and loosen it with light taps of a hammer on the handle of the screwdriver. If necessary, use the other flats.

Now lift the protective flange slightly.

If necessary, squeeze the retaining clips of the return line from the inside of the flange (as already done from the outside) and pull the line downward.

Reach into the fuel tank and remove the sender from the fuel pickup housing while pressing the locking tab.

Disconnect the fuel sender connector on the protective flange.

Before installation, wet the protective flange O-ring with fuel.

Installation position of the protective flange: the arrow on the flange must align with the mark on the fuel tank.

Test yourself

A quick Audi 80 quiz: every answer comes with an explanation and a link to the manual page.