Fuel Level Sensor -G-, CHECKING (A5 THROUGH MY 2011, A4 THROUGH MY 2012, VEHICLES WITH FWD AND AWD)

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Special tools and workshop equipment required

Analog/Digital Multimeter FLU83III
Connector Test Set VAG1594D

Procedure

Fig 1: Identifying Cover Bolts For Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- Remove the rear bench seat. Refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

-- Remove the locking flange cover -arrows-.

-- Disconnect the connector -1- on the sealing flange.

Fig 2: Disconnect Connectors

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore item -2-.

-- Push the circlip -1- upward in direction of -arrow A- and squeeze the release in direction of -arrow B-.

Fig 3: Pulling Lock -1- Upward -Arrow A- & Press -Arrow B-

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The Fuel Level Sensor -G- is Installed

Fig 4: Fuel Level Sensor Connector Terminals

Courtesy of AUDI OF AMERICA, LLC

-- Connect the analog/digital multimeter to measure the resistance between contacts -2 and 3-.

Fuel tank empty: approximately 60 Ω.
Fuel tank full: approximately 275 Ω.

-- Connect the analog/digital multimeter to measure the resistance between contacts -2 and 4-.

Fuel tank empty: approximately 280 Ω.
Fuel tank full: approximately 65 Ω.

-- Connect the multimeter to measure the resistance between contacts -3 and 4-.

Arbitrary sensor position: about 340 Ω.

The Fuel Level Sensor -G- is Removed

Fig 5: Fuel Level Sensor Connector Terminals

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To check resistance values "Tank full" or "Tank empty", the Fuel Level Sensor -G- must be removed (refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING ) and the floater on the sensor must be placed in the upper or lower end position. Refer to.

The following values are obtained when the fuel level sensor is removed because of the greater movement of the floater arm:

-- Connect the analog/digital multimeter to measure the resistance between contacts -2 and 3-.

Sensor at lower stop: approximately 52 Ω.
Sensor at upper stop: approximately 283 Ω.

-- Connect the analog/digital multimeter to measure the resistance between contacts -2 and 4-.

Sensor at lower stop: approximately 288 Ω.
Sensor at upper stop: approximately 57 Ω.

-- Connect the multimeter to measure the resistance between contacts -3 and 4-.

Arbitrary sensor position: about 340 Ω.

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 delivery unit. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

-- Install the sealing flange cover. Refer to Figure.

-- Install the rear bench seat. Refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .