My 1.8T, in my garage, no starter action, battery fine. Had it sent to garage, where the bill for a replacement was $800,including 3 hours labor. Visions of my 98 Subaru, where I could get the starter out and in under half an hour. Does this seem like a reasonable amount? Bear in mind I live in an expensive zip code.

And then, there's my problem with the car running out of gas at 1/4 tank. A problem with the fuel pump or sending unit or transfer line between the tank halves. They're getting me a price for that, but apparently, all the parts w labor are $2k. Is a fuel pump really that expensive? Thank goodness I can wait until it gets warmer up here in CT, because it can't be that hard of a job, and I'll do it myself.

​​​​Or since my old shop just closed have I managed to find an Uber-expensive replacement?

 

$2k for fuel pump is way steep and it's about a 15 minute job. An OEM pump from the dealer is about $450 and fuel filter around $50. Fuel pump replacement only involves removing the rear bench seat cushion, removing a few screws for cover, disconnecting the lines, and twist and pull the old one out. Install is reverse. Filter is another 15 minutes to remove undercarriage cover, 1 screw on holder, and quick disconnect lines. I'd try only replacing the pump and filter first. It's important to do the filter at the same time as a bad one will ruin the new pump quickly. My 1.8T was running out around a quarter tank when I first purchased and a $60 aftermarket pump w/sending unit fixed it.

$800 for an alternator is also a bit steep even with a brand new Bosch unit and not reman. If they billed you for 3 hours, they're billing you on some kind of book time, not actual time, or did it the hard way and put front end in service position. It's really only a 15 minute job. The quick way is to remove the intake tube on throttle body to get access to fan bolt, remove bolt and remove fan, and then you have easy access to lower alternator bolt. Talking about 3 bolts here so they billed you an hour a bolt.

Tough to find an honest mechanic/shop. Reason why I learned to work on everything myself at a young age.

 

Thanks for the reply. It was the starter, not the alternator that needed replacing. If I had a warm spot to work, and could get to it if the car was on ramps, I would have tried for a new starter solenoid. But it's cold, I don't have time, needed the car and my old shop closed, so there it was.

On the gas tank, I'd really like to understand how things work in there. I have Quattro, so have the saddle-shaped tank with two access ports. On the passenger side (I guess) is the fuel pump and on the driver's side is the sending unit. Then there's the part I don't quite understand - the tube that goes from the sending unit side to the fuel pump side. This transfers fuel when the level in the tank drops below the highest part of the "saddle." It seems to me that this tube is not functioning, and therefore when the fuel level gets that low, the amount in the left side is "marooned," causing a runout at around 1/4 tank.

How does that fuel in the tube get transferred? Is it pushed by another little pump associated with the sending unit (which seems to work fine btw)? Or is it pulled through by the operation of the fuel pump?

I should mention that my fuel pump has been not up to par for about a year now. It used to be "turn the key - bang - it would start." Now it cranks for a few seconds, but I don't let it go that long. I turn off the starter, then turn it on again, it starts right up. So I will definitely put in another pump (filter is new). I appreciate what you said about your putting in a new pump and it curing your out of gas at 1/4 tank problem, but why do you think that was? Certainly I can start there, putting in a new pump and then see if it solves the problem.

What do you think? Thx.

 

The Audi tts are renowned for bad cluster gauges. Could it be a failed gauge? There is a way to code the fuel consumption. But normally that’s done after some upgrades like fuel injectors etc. s4 wiki tuning has all that information. I would never pay 800 for a starter replacement unless I had a sugar momma with oodles of cash....

 

That's even worse for the starter because difficulty is about the same and cost around $300 for OEM Bosch unit. Just a couple bolts, but some people disconnect the cat for better access although it's not necessary.

Fuel pump is on passenger side (right). Fuel level sensor is on driver's side (left) and essentially just a float for showing level at gauge cluster. I'm not 100% familiar, but there is a suction pump (8E0201865D) that's typically sold separately and connected to the bottom of level sensor. It is #36 in this diagram (https://www.jimellisaudiparts.com/sh...roduct=5647801). Looking at that diagram, the top of the level sensor is connected to return line. Hose from that goes to one side of suction pump at Y in #36. Can't tell from diagram, but I'd imagine both lines off suction pump connect to fuel pump side.

You can test the level sensor to rule it out. If the fuel pump isn't making noise, it's probably fine, and might only be the suction pump. On mine, I only replaced the fuel pump. It was shortly after I bought it. It had a 1/4 tank, was buzzing, and started sputtering up hills and eventually stalled out. Has been fine since replacing.


Here is an additional photo I found with it attached to level sender. You may want to try just blowing the hoses out with air and cleaning them to make sure they aren't clogged. Check them for damage too.

 

A lot to look at. Thanks a lot.

 

Those tank covers are not hard to open, so when fuel is getting close to "1/4" tank, you could take a look to see whether the passenger side, where the pump is, is close to empty. Be aware that these covers are below fuel level when the tank is say 1/2 full, so be cautious when removing them.

 

Good advice on the cover removal! I didn't know about them being below the gas level when the tank was relatively full. I wouldn't have done this except at low levels, but still.

This whole project is going to wait (I hope) until the spring/summer. My fingers don't do well in the CT winter

 

Pack up and move out this way! 70F here today, 77F on Friday.

 

Sigh....