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If you determine that the sending unit is at fault (using Phil's method) I would highly recommend the VDO-226001 sending unit. It is reasonably priced ($25) and available from many suppliers (I got mine from JEGS Hi Performance). This unit is a direct fit to the tank, is the same resistance [~20-180 ohm] and is adjustable as to float level.
I am using them in both my 444 and 220 wagon with the orig. dash units. They have been in use for several years and are accurate and more 'steady' than the original senders. The float adjustment covered the difference in tank 'depth' easily.
Cheers!
OK
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