[s-cars] Low fuel gauge level

[Varon H. Fugman]

>>first it would only read a hair
under full then eventually only 7/8 full, now at 3/4 full.

Harold,

Sounds like the float has a leak and is gradually taking on gasoline, as
opposed to a broken wire.  However, it is also possible but not likley that
it could be a bad connection or a problem with the gauge.  I think there is
a resistance spec for the sender, i.e. what the resistence should be at
full, 3/4, etc.  Does anyone have this?

If it is the float, replacement of the fuel sender assembly (~$100) is
required.

Not too hard, but does involve spending some time with your head and upper
torso in the trunk!  Try to have the fuel level as low as possible before
you start (1/4 would be fine) and have good ventilation when you have the
tank open (i.e. sender assembly removed.)  Also, after you remove the metal
plate in the trunk but before you remove the sender assembly, clean the area
throughly... there will be a lot of dirt there, and you don't want it
falling into the tank.

The sender assembly includes the float mechansim and the round white plastic
part that sits on the top of tank and has the connections for all the
plumbing and wiring.  As you take it out, note how the line and wires to the
fuel pump are routed.  You'll need to disconnect these, and it will be
easier to put the new one in if you get it right.  Plus, you don't want the
hose/wires to the fuel pump to get in the way of the float mechansim.

Our cars use 3 lines (supply, return, and vent) but the new Audi part has 4
connections.  You should get a rubber cap to seal off the unused connection.

Varon
'95 urS6