Fuel Level Sensor -G-, Checking

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Special Tools And Workshop Equipment Required

Analog/Digital Multimeter FLU 83III
Connector Test Set VAG 1594D
Elbow Assembly Tool T10118

Procedure

Fig 1: Identifying Cover Bolts For Locking Flange

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Fold the insulation mat near the locking flange cover to the side.

-- Remove the bolts -arrows- and the locking flange cover.

NOTE:

Ignore item -1-.

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

Fig 2: Identifying Connectors

Courtesy of AUDI OF AMERICA, LLC

The Fuel Level Sensor -G- is Installed:

Fig 3: Identifying Fuel Level Sensor -G-

Courtesy of AUDI OF AMERICA, LLC

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 (0.3 mile) after filling the fuel tank full to get rid of any bubbles in the fuel tank. Then fill the fuel tank again.

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

Measurement at contact	Tank empty	Tank full
2 + 4	254 to 276 Ω	53 to 71 Ω
2 + 6	86 to 64 Ω	287 to 269 Ω
4 + 6 ¹⁾	approximately 340 Ω	approximately 340 Ω
¹⁾ Arbitrary sensor position

The Fuel Level Sensor -G- Is Removed:

Fig 4: Identifying Fuel Level Sensor -G-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To check resistance values "tank full" or "tank empty", the fuel delivery unit must be removed and the sensor floater must be moved in upper or lower end position.

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

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

Measurement at contact	Tank empty	Tank full
1 + 3	maximum 53.4 Ω	minimum 272.7 Ω
2 + 3	minimum 272.7 Ω	maximum 53.4 Ω
1 + 2 ¹⁾	approximately 340 Ω	approximately 340 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.

-- Remove and install the fuel delivery unit/fuel level sensor, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .