Fuel Level Sensor -G-, CHECKING

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Analog/Digital Multimeter FLU83III
Connector Test SetVAG1594D
Carpet knife, commercially available

Procedure

Fig 1: Cut The Floor Covering Along The Perforation

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-- Remove the right rear single seat in the second row of seats, refer to Seat Frames .

WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

-- Fold carpet cut-out to side -arrow-.

Fig 2: Identifying Locking Flange Cover - Tightening Specifications

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-- Remove nuts -1 to 4- and remove right locking flange cover.

Version 1:

Fig 3: Locking Flange Cover

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-- Disconnect the connector -4- on the right locking flange.

NOTE:

Ignore -1, 2 and 3-.

-- Connect multimeter between terminals -2 and 3- to measure resistance.

Fig 4: Identifying Terminals -2- And -3- For Resistance Measurement

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Version 2:

Fig 5: Locking Flange Cover

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-- Disconnect the connector -3- on the right locking flange.

NOTE:

Ignore items -1, 2 and 4-.

-- Connect multimeter between terminals -1 and 2- to measure resistance.

Fig 6: Fuel Level Sensor Location

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Continuation for All Vehicles

The Fuel Level Sensor -G- is installed:

Sensor at lower stop: 863 to 960 Ω.
Sensor at upper stop: 67 to 86 Ω.

NOTE:

If measured value is 0 Ω there is a short circuit. If measured value is ∞ Ω there is and open circuit in the wiring.

To check resistance values "Tank full" or "Tank empty", the Fuel Level Sensor -G- must be removed and the floater on the sensor must move to the upper or lower end position, refer to Fuel Level Sensor -G-, REMOVING AND INSTALLING .

The following values are obtained when the Fuel Level Sensor -G- is removed because of the greater movement of the floater arm:

The Fuel Level Sensor -G- is removed:

Fig 7: Fuel Level Sensor Connector Terminal Identification

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-- Connect multimeter between terminals -1 and 2- to measure resistance.

Sensor at lower stop: approximately 990 Ω.
Sensor at upper stop: approximately 51 Ω.

Assemble in reverse order of disassembling. Note the following:

-- Install the right locking flange cover, refer to Figure.

-- Insert the frame into the floor covering, refer to the Parts Catalog and Interior Trim .

-- Install the right rear single seat in the second row of seats, refer to Seat Frames .