Fuel Gauge (G1) Checking: Notes

Tools required

Instrument tester VW 1301
Digital multimeter Fluke 83 (US 1119)
Connector test kit V.A.G. 1594/A
Applicable wiring diagram
Applicable repair procedure. See appropriate FUEL SUPPLY article.
Approved fuel storage cart, such as Tempo Products FM 3000 or equivalent

CAUTION: DO NOT damage, enlarge or bend connector terminals or cavities by forcing probes into them when performing electrical checks. Use connector test kit VW 1594 to make the necessary electrical connections.

WARNING: When working on open fuel system:

Fire hazard and danger of explosion! Do not smoke. Keep away anything that can ignite fuel or fuel fumes.

Before removing or installing fuel level sensor, the suction pipe of a workshop exhaust system must be located near the fuel tank opening to immediately suck gas vapors away. If no exhaust system is available use a radial fan (motor must be located outside the air flow) with a volume of at least 15m³ /hr (9cfm).
Wear fuel resistant gloves whenever working on open fuel system.

NOTE:

If the wiring to the Fuel Level Sensor (G) has an open or short circuit, the gauge needle will remain on the left side of the scale.
Ensure ignition is switched off when filling fuel tank, otherwise the correct fuel level indication will only be present after a long delay.
The fuel gauge needle will only move when more than 4 liters (one gallon) are in the tank. Less fuel will not affect the needle.
In the even that the fuel tank was filled completely with the ignition switched on (full fuel level indication after a long delay), the gauge can be corrected by disconnecting and reconnecting the battery ground (GND) strap or accessing the Instrument Cluster DTC.

Test conditions:

Fuses S 16 and S 21 on fuse/relay panel OK