Audi Parts Catalog Audi Accessories Catalog Audi Technical Articles VW-Audi Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
Audi A4 Oil Level Sensor Replacement
 
Bookmark and Share

Pelican Technical Article:

Audi A4 Oil Level Sensor Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$40

Talent:

**

Tools:

19mm socket, 5mm Allen

Applicable Models:

Audi A4 (2002-05)
Audi A4 Cabriolet (2003-06)

Parts Required:

Oil Level Sensor, Oil

Hot Tip:

Change the filter while your there

Performance Gain:

Proper working gauge

Complementary Modification:

Change your oil filter

If you drive an Audi A4 there is a very good chance you already know about the oil level sensor and never ending problems with the ever present oil warning light on the dashboard. These cars are notorious for problems with the sensor failing and then causing other electrical problems within the sensor system.

The oil level sensor on the Audi A4 uses the temperature of the oil to determine the level of oil in the tank. These sensors are prone to failure and the whole system can be a source of frustration leaving you staring at the yellow oil light. If your oil level light comes on the first thing you should do is check the fuse for the sensor.

Remove the cover on your fuse box and check the appropriate fuse before replacing anything. Remove the fuse and check the condition of it. Sometimes these fuses can fail and you cannot see the damage. If you have a spare fuse you should install it and see if that clears up the problem. (Fuse is #5 in the driver side panel. It's not noted on the backside of the panel, but in the Manuel it states the #5 10amp controls the oil level sensor.)

Next you want to check the wiring. The wiring system in these cars have shielding that is very attractive to small creatures and many people have found that the wiring loom was the problem after replacing the sensor. The area where the wires enter the sensor are a known weak point for damage from exposure to the elements, especially if the under body tray is missing. Make sure to inspect this area well.

After checking all of these potential issues you are left with replacing the sensor itself. There is no good cheap way to test the sensor so it is easier to replace it.

The oil level sensor is located on the bottom of the oil pan, which means you will have to drain the oil in the engine to perform this work; therefore you might as well change the oil filter while you are performing this job to save you time and money in the long run. Please see our article on changing your oil and filter.

Safely jack up and support your car.
Figure 1

Safely jack up and support your car. With the car safely off the ground you will need to remove the engine tray. A great many of these cars have had the engine trays removed over the years and not replaced or replaced with different hardware or fasteners. The front tray and transmission tray share three common fasteners (green arrows). To remove the front tray remove the three common fasteners (green arrows), the eight under tray fasteners (red arrows) and the two fasteners in the wheel well (yellow arrows). Then lower the tray down and out from the engine area. Use care when lowering it. If you have had any leaks there can be fluid stored up in the tray.

You will need to drain the motor oil to replace the level sensor.
Figure 2

You will need to drain the motor oil to replace the level sensor. On the front section of the oil pan you will find the oil drain plug (red arrow) and the oil level sensor (yellow arrow).

Begin by draining the oil.
Figure 3

Begin by draining the oil. Use a 19mm socket and remove the drain plug (red arrow). Try not to drop the drain plug in the container you are using to catch the oil. Always dispose used motor oil according to the regulations where you live. Most oil change shops or your neighborhood parts store will take your old oil and filter to be recycled properly.

Once the oil has emptied reinstall the drain plug with a new crush washer (red arrow).
Figure 4

Once the oil has emptied reinstall the drain plug with a new crush washer (red arrow). I always like to make sure I reinstall the drain plug before I start working any where else just so I don't forget it later.

Once again, make sure you have double checked the wiring before installing the new sensor.
Figure 5

Once again, make sure you have double checked the wiring before installing the new sensor. The wiring connection from the harness to plug is a known weak spot (red arrow).

Carefully release the clip on the connection and separate the wiring connection from the sensor (red arrow).
Figure 6

Carefully release the clip on the connection and separate the wiring connection from the sensor (red arrow). These clips get very brittle over time so use care when removing.

Use a 5mm Allen and remove the three bolts holding the sensor to the bottom of the pan (red arrows).
Figure 7

Use a 5mm Allen and remove the three bolts holding the sensor to the bottom of the pan (red arrows). Oil will still escape through this opening even after you drain the oil so be prepared to catch it and properly dispose of it.

When installing the new sensor make sure to clean around the opening so the base of the sensor (red arrow) will sit flat and flush against the oil pan.
Figure 8

When installing the new sensor make sure to clean around the opening so the base of the sensor (red arrow) will sit flat and flush against the oil pan. Always replace the O-ring around the base of the sensor. Installation is the reverse of removal. Do NOT forget to refill the motor with oil!



Bookmark and Share
Comments and Suggestions:
Lussy Comments: I found #5, it was burnt, replace it and goes away the fault. My park distance started to work as well after the fuse replacement.
Same day after 40km's the oil level sensor came back, the fuse is still OK and everything still works fine but the level sensor still shows. What must I do. VAG it and supress it.
August 28, 2016
  Followup from the Pelican Staff: If working now, you can use any stored fault codes to put you in the direction of the cause. - Nick at Pelican Parts  
Lussy Comments: My A4 2.0tdi BRD engine 2007. I changed the sensor and crimp the new plug but the light stays on the dashboard. When you remove the battery terminal the light goes away, immediately you switch off an start the car again it comes back. I'll check the fuse #5 and see if that could be the problem
August 25, 2016
  Followup from the Pelican Staff: Are you sure it is oil level and not pressure? Have you checked for fault codes? - Nick at Pelican Parts  
deruitem Comments: Looking to replace the harness that goes to the oil level sensor as mine has been cut on my 2001 2.8. Looking for a part number and where it connects on the other side
August 2, 2016
  Followup from the Pelican Staff: You will likely have to buy the connector and terminals, then crimp and shrink it on.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
jrc1277 Comments: Thanks I found it. Its #5 in the driver side panel. Its not noted on the backside of the panel but in the Manuel it states the #5 10amp controls the oil level sensor.
March 23, 2016
  Followup from the Pelican Staff: Thanks for the follow up. We appreciate it.
- Nick at Pelican Parts
 
jrc1277 Comments: Can you tell me the location of the fuse for the oil sensor? I cannot find any info on its location.
"If your oil level light comes on the first thing you should do is check the fuse for the sensor."

Thank you
Josh Cole
March 15, 2016
  Followup from the Pelican Staff: I am going to have the info added to the article. Fuse number, location, etc. - Nick at Pelican Parts  

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Sat 12/3/2016 02:46:02 AM