Fuel Level Sensor 2 -G169-, 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
Elbow Assembly Tool T10118

Procedure

Fig 1: Identifying Cover Bolts For Locking Flange

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The electric wires for Fuel Level Sensor 2 -G169- are routed to the fuel pump locking flange inside the fuel tank.

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

-- Remove the locking flange cover -arrows-.

-- Open the connector locking mechanism with the Elbow Assembly Tool T10118 and disconnect the connector -2- on the locking flange.

Fig 2: Disconnect Connectors

Courtesy of AUDI OF AMERICA, LLC

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

-- 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-

Courtesy of AUDI OF AMERICA, LLC

Fuel Level Sensor 2 -G169- is Installed

Fig 4: Connect Multimeter Between Terminals

Courtesy of AUDI OF AMERICA, LLC

-- Connect the multimeter for the resistance measurement between terminal -1- on the connector -A- and terminal -2- on the connector -B-.

Tank empty: approximately 50 Ω.
Tank full: approximately 295 Ω.

-- Connect the multimeter for the resistance measurement between terminal -2- on the connector -A- and terminal -2- on the connector -B-.

Tank empty: approximately 290 Ω.
Tank full: approximately 45 Ω.

-- Connect the multimeter between terminals -1 and 2- on connector -A- to measure the resistance.

Arbitrary sensor position: about 340 Ω.

Fuel Level Sensor 2 -G169- is Removed

Fig 5: Fuel Level Sensor 2 -G169- 3 Pin Connector

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To check resistance values "tank full" or "tank empty", the Fuel Level Sensor 2 -G169- must be removed (refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING .) and the sensor floater must be moved in upper or lower end position.

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

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

Sensor at lower stop: approximately 290 Ω.
Sensor at upper stop: approximately 16 Ω.

-- Connect the analog/digital multimeter to measure the resistance between contacts -1 and 3-.

Sensor at lower stop: approximately 50 Ω.
Sensor at upper stop: approximately 324 Ω.

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

Arbitrary sensor position: about 340 Ω.

The Fuel Level Sensor 2 -G169- is faulty if the following is found:

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

-- Install Fuel Level Sensor 2 -G169-. Refer to Fuel Level Sensor 2 -G169-, 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 .