Fuel Level Sensor -G-, Checking

Special Tools And Workshop Equipment Required

Analog/Digital Multimeter FLU 83III
Connector Test Set VAG 1594D
Scissors

Procedure

Fig 1: Identifying Locking Flange Cover & Bolts -Arrows-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The fuel tank must be filled completely in order to have an exact reading of the resistance from the "sensor at upper stop" when it is installed. Drive at least 500 meters (546 yards) after filling the fuel tank full to get rid of any bubbles in the fuel tank. Then fill the fuel tank again.

-- Move the right front seat all the way forward.

-- Remove the rear bench seat or right rear single seat, refer to Rear Seats .

-- Cut the insulation mat near the sealing flange cover (in direction of travel on the right side under the rear seat) with scissors along the perforation and fold to the side.

-- Remove the bolts -arrows- and remove the sealing flange cover -1-.

-- Release the connector safety catch, and disconnect the connector -1- on the sealing flange.

NOTE:

Ignore item -2-.

Make Sure the Fuel Level Sensor -G- is in the Installed Position

Fig 2: Identifying Connectors

Courtesy of AUDI OF AMERICA, LLC

Fig 3: Fuel Level Sensor Connector Terminal Identification

Courtesy of AUDI OF AMERICA, LLC

-- Connect the multimeter for resistance measurements shown in the table.

Measurement At Contact	Tank Empty	Tank Full
1 + 2	255 to 281 Ω	maximum 70 Ω
1 + 3	59 to 85 Ω	minimum 270 Ω
2 + 3 ¹⁾	335 to 345 Ω	335 to 345 Ω
¹⁾ Arbitrary sensor position

Check the Fuel Level Sensor -G- when it is Removed

Fig 4: Fuel Level Sensor Connector Terminal Identification

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To check resistance values "tank full" or "tank empty", the fuel level sensor must be removed, refer to FUEL LEVEL SENSOR -G-, REMOVING AND INSTALLING , and the sensor floater must be moved to the upper or lower stop.

With fuel level sensor removed, the following values are obtained because of the greater deflection of the floater arm:

-- Connect the multimeter for resistance measurements shown in the table.

Measurement at Contact	Tank Empty	Tank Full
1 + 2	approximately 278 Ω	approximately 65.5 Ω
1 + 3	approximately 62 Ω	approximately 274.5 Ω
2 + 3 ¹⁾	335 to 345 Ω	335 to 345 Ω
¹⁾ Arbitrary sensor position

The Fuel Level Sensor -G- is faulty when the following is detected:

Large deviations in measured values
Measured value 0 Ω (short circuit).
Measured value ∞ Ω (open circuit).
No fault in the electric wires.

-- Install the Fuel Level Sensor -G-, refer to FUEL LEVEL SENSOR -G-, REMOVING AND INSTALLING .