Geber für Kraftstoffmangel G210 / A6 Bj.98 AFB | Posts 16+

"Yes, I understand your ideas, and I'd like to test them too. However, the problem is that if the error occurs and the light starts blinking, I can't just stop anywhere on the highway and take apart my entire trunk. I'm usually on my way somewhere, and I can't afford to run out of diesel and have to stop. I also have to work, so I don't have much free time besides refueling. That's the problem. And the next crucial issue is that the light doesn't blink constantly; it turns off again after about 1-2 minutes. So, by the time I find a suitable place to "tinker," the light is off again, and then I don't need to look at it anymore because the fuel tank will be full when it turns off again. I don't know how to test it because the light turns off intermittently, and then I need to have diesel available."
The fuel tank can't be empty and then full again, especially since the fuel level in the tank is different each time it happens. Also, I can trigger it by driving at full speed, like on the highway with my foot on the gas. How is that possible?
"On the other hand, just recently I was driving at a constant 100 km/h, and something happened. I don't know what triggered it, and I can't say exactly when it started, but it's not right before the red zone; it's already happening when the fuel gauge is about half full, and the fuel filler cap is definitely full."
I'm completely frustrated. I'll refuel, and then it will be quiet again, but it will reappear. At the location where the error first occurred, nothing happens after refueling. No one knows when it will happen again. While driving, I'm constantly looking to see if the light starts flashing. I'm really at a loss. Sometimes I think that stupid fuel level sensor is malfunctioning or has some kind of issue, because it's impossible to understand what's causing the error, regardless of the fuel level; it just starts flashing whenever it feels like it.
I was thinking about disassembling the pump, but there's not much technology involved; it's just a switch that's closed or opened by a small float. What do you think about that? And I can't test whether the centrifugal pump in the dust container sometimes gets stuck because when I had it outside, it worked perfectly. If I could get this small pump separately, but at the , they only sell it as a complete unit for a crazy amount of money.
Oh man, what am I going to do...?

Either take the time to reproduce the error, immediately identify the cause, and check the relevant components, or replace the sender and/or pump based on suspicion.
You could monitor the pump's power consumption by inserting an ammeter between the pump and the switch, and potentially using an ohmmeter connected in series. This would allow you to immediately see what's happening with the components at the time of a fault.
If the pump becomes blocked, you will notice it by the increased power consumption.

Could it be that the T-fitting is faulty? It's not normal for it to just drip from behind. The idea about using foam also sounds interesting.
You can avoid the problem by only letting the tank get to 1/4 empty and then refilling it. If you have time and are wearing the right clothes, then you can perform the tests mentioned here, and you will eventually find what you're looking for.

See you later.