Operation CHARM: Car repair manuals for everyone.

Fuel Gauge: Adjustments

Fuel gauge, checking and adjusting

Checking

- Open trunk lid and pull back carpet from right-front side of trunk.




- Pry off plastic cover using screwdriver.

Note: When installing, glue carpet back in using a spray adhesive (available locally).




- Disconnect fuel level sensor connector.
- Set digital multimeter (Fluke 83 or equivalent) to voltage measuring range.
- Connect multimeter between fuel level sensor connector terminals.
- Switch ignition on.
Specification: 9.75-10.3 volts

- Switch ignition off.

If specified value is not obtained:
- Check for open circuit in wiring according to wiring diagram, repair as necessary.
- Check voltage stabilizer. Testing and Inspection




- Using VW 1594 connector test kit, connect VW 1301 instrument/gauge tester between fuel level sensor connector terminals as shown.
- Adjust VW 1301 to setting of 280.
- Switch ignition on for at least 2 minutes.




- With VW 1301 set to 280, fuel gauge needle must lie on right edge of 3rd red mark in reserve area (arrow).
- While testing, tap gently on the glass of the instrument cluster with a finger to aid needle movement.

Note: When reconnecting the fuel level sensor connector, ensure that the connector terminals are not pushed out of the housing.


Adjusting

If needle position is not as specified:
- Cover instrument cluster glass in area of fuel gauge with a soft, clean cloth (to prevent scratching).
- Using pliers, carefully remove cap for fuel gauge adjusting screw.




- Using hex key or small screwdriver, turn adjusting screw-A- until fuel gauge needle lies on right edge of 3rd red mark in reserve area (arrow).

Notes:
While adjusting the fuel gauge, keep tapping gently on the instrument cluster glass. Do not start the engine.
When reconnecting the fuel level sensor connector; make sure that the connector terminals are not pushed out of the housing.

If needle position is still not as specified:
- Replace fuel gauge.