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Audi a4 1999 1.8 turbo. fuel guage stopped working?

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Common problem on these cars. There's a wire on the sending unit that is run under the float arm. It gets frayed and then breaks and the gauge stops working.

Pull up the carpet in the trunk, and behind the passenger side rear seat is the access port. Open it up to get access to the tank. The large black sealing washer/nut around the outside is really tight. What I did to open it up was to push with two screwdrivers, directly across from each other and in opposite directions, to turn it. Reach way down in and pull out the sending unit. You'll need to unplug the black harness plug from the pump assembly up near the top (you'll see what I mean when you get in there). The wire is likely broken. You can splice the two ends together using two crimp connectors and a jumper wire - route them up and over the float arm rather than under it (that was a stupid idea on some Audi engineer's part). While you have the sender out, clean up the electrical contacts on it with electrical contact cleaner - it's worth the 30 seconds to a minute that it'll take. Then reassemble it all and you're good to go.

It may sound like a lot of work, and may seem kind of aggravating, but I think it took me less than 15 minutes total, from pulling up the carpet to reinstalling it. It's a very easy DIY fix, and 99% of the time that this happens on an Audi A4, it's either that wire that has broken, or dirty contacts. There's very rarely any need to buy another $85 sending unit.

Posted on Jul 29, 2008

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