Fuel Level Sensor -G-, CHECKING, VEHICLES THROUGH MY 2012

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Special tools and workshop equipment required

Analog/Digital Multimeter FLU83 III
Connector Test Set VAG1594D

Procedure

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

Courtesy of AUDI OF AMERICA, LLC

-- Remove 1/3 of the rear seat, refer to REAR SEAT, REMOVING AND INSTALLING .

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

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

Fig 2: Identifying Connector -1- On Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- 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

The Fuel Level Sensor -G- is Installed

NOTE:

The fuel tank must be filled completely in order to have an exact reading of the resistance on the "Fuel tank full" 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.

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

Fig 4: Fuel Level Sensor Connector Terminals

Courtesy of AUDI OF AMERICA, LLC

Fuel tank empty: approximately 285 Ω.
Fuel tank full: approximately 60 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 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-.

Fuel tank empty: approximately 285 Ω.
Fuel tank full: approximately 53 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/Fuel Level Sensor -G-, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .

-- Install the sealing flange cover, refer to Figure.

-- Install 1/3 of the rear seat, refer to INSTALLING .