Fuel Level Sensor 2 -G169-, 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

CAUTION:

There is the risk of incorrect measurements.

When measuring the resistance values at "fuel tank empty", an inaccurate measurement, can occur because there may be some fuel left in the other chamber. The remaining fuel must be extracted after opening the locking flange in order to attain the following measured values, refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING .

Fuel level sensor 2 -G169- 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	65 Liter Tank (17.17 gallons)		75 Liter Tank, Full (19.81)
Measurement at contact	Tank empty	Tank full	Tank empty	Tank full
1 + 3	249 to 286 Ω	51 to 146 Ω	249 to 286 Ω	51 to 90 Ω
1 + 5	54 to 91 Ω	289 to 194 Ω	54 to 91 Ω	289 to 250 Ω
3 + 5 ¹⁾	approximately 340 Ω	approximately 340 Ω	approximately 340 Ω	approximately 340 Ω
¹⁾ Arbitrary sensor position

Fuel level sensor 2 -G169- 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 level sensor must be removed and the sensor floater must be moved to the upper or lower stop.

With fuel level sensor 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 55 Ω	minimum 281.8 Ω
2 + 3	minimum 281.8 Ω	maximum 55 Ω
1 + 2 ¹⁾	approximately 340 Ω	approximately 340 Ω
¹⁾ Arbitrary sensor position

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 .