Fuel Level Sensor 2 (G169), Checking

Fuel Level Sensor 2 (G169), Checking

Special tools, testers and auxiliary items required

• Multimeter (V.A.G 1526E)

• Connector Test Set (V.A.G 1594C)

Procedure






- Move the right front seat all the way forward.

- Remove the rear bench seat.

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

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

- Disconnect the connector - 2 - on the locking flange.






• Ignore - 1 -.

Risk of an inaccurate measurement.

• 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) ] Fuel Level Sensor 2 (G169).

Fuel level sensor 2 installed:






- Connect the multimeter to measure the resistance between contacts - 1 and 3 -.

• Empty tank: 249 to 286 ohms.

• 65-Liter-full tank: 51 to 146 ohms.

• 75-Liter-full tank: 51 to 90 ohms.

- Connect the multimeter to measure the resistance between contacts - 1 and 5 -.

• Empty tank: 54 to 91 ohms.

• 65-Liter-full tank: 289 to 194 ohms.

• 75-Liter-full tank: 289 to 250 ohms.

- Connect the multimeter to measure the resistance between contacts - 3 and 5 -.

• Any sensor position: Approximately 340 ohms.

• The fuel tank must be filled completely in order to get an exact reading of the resistance on the "fuel tank full" when it is installed. Drive at least 500 meters after filling the fuel tank full to get rid of any bubbles in the fuel tank. Then fill the fuel tank again.

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

• With fuel level sensor 2 removed, the following values are obtained because of the greater deflection of the floater arm:

Fuel level sensor 2 removed:






- Connect the multimeter to measure the resistance between contacts - 1 and 3 -.

• Sensor at lower stop: Highest 55 ohms.

• Sensor at upper stop: Lowest 281,8 ohms.

- Connect the multimeter to measure the resistance between contacts - 2 and 3 -.

• Sensor at lower stop: Lowest 281,8 ohms.

• Sensor at upper stop: Highest 55 ohms.

- Connect the multimeter to measure the resistance between contacts - 1 and 2 -.

• Any sensor position: Approximately 340 ohms.

- Replace fuel level sensor 2 if there is a large deviation in the measured value from 0 ohms (short circuit) or measured value infinity ohms (open circuit) and if no faults are found in the electric wire.

- Install fuel level sensor 2. Refer to => [ Fuel Level Sensor 2 (G169) ] Fuel Level Sensor 2 (G169).