FWD

Fuel Level Sensor, Checking

Special tools, testers and auxiliary items required

• Hand-Held Multimeter (V.A.G 1526C)

• Connector Test Set (V.A.G 1594C)

Procedure

- Remove rear seat bench.

- Unclip the retainers - arrows - of the cover for sealing flange.





- Disconnect electrical harness connector - arrow - at locking flange.





Vehicles through approximately 11/2004:

• On vehicles with 2-wire sensor technology, the connector for fuel level sensor (G) is equipped with 4 terminals.

- Connect multimeter between terminal - 2 - and - 3 - for resistance measurement.





Fuel level sensor installed:

• Sensor at lower stop: approximately 270 ohms.

• Sensor at upper stop: approximately 70 ohms.

• To check resistance values tank full or tank empty, the fuel delivery unit must be removed. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit and the sensor floater must be placed in upper or lower end position.

• If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring.

• With fuel level sensor removed, the following values are obtained because of the greater deflection of the floater arm:

Fuel level sensor removed:

• Sensor at lower stop: approximately 290 ohms.

• Sensor at upper stop: approximately 54 ohms.

Assembly is in reverse order of removal, note the following:

- Install rear seat bench.

Vehicles from approximately 11/2004:

• On vehicles with 3-wire sensor technology, the connector for fuel level sensor is equipped with 5 terminals.

- Connect multimeter between terminal - 2 - and - 3 - for resistance measurement.





Fuel level sensor installed:

• Sensor at lower stop: approximately 270 ohms.

• Sensor at upper stop: approximately 70 ohms.

• To check resistance values on tank full or tank empty, the fuel delivery unit must be removed. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit and the sensor floater must be placed in upper or lower end position.

• If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring.

• With fuel level sensor removed, the following values are obtained because of the greater deflection of the floater arm:

Fuel level sensor removed:

• Sensor at lower stop: approximately 290 ohms.

• Sensor at upper stop: approximately 50 ohms.

- Connect multimeter between terminal - 3 - and - 4 - for resistance measurement.

Fuel level sensor installed or removed:

• Arbitrary sensor position: approximately 340 ohms.

Assembly is in reverse order of removal, note the following:

- Install rear seat bench.