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)

• Window Cutter (V.A.G 1561A)

• Blade (L-shaped, 25.4mm) (V.A.G 1561/22)

• Scissors

Procedure






- Move the left front seat all the way forward.

- Remove the rear bench seat or the left lower seat frame/rear seat backrest.

- Cut the insulation mat near the locking flange cover along the perforation with scissors and fold it to the side.

- Cut through the sealing around the locking flange cover with the (V.A.G 1561A) and (V.A.G 1561/22).

- Remove the locking flange cover.

- Repair damaged painted surfaces.

- Apply corrosion protection if necessary.

- Disconnect the connector - 1 - on the locking flange.






Checking Fuel Level Sensor 2 when it is Installed






- Connect the multimeter to measure the resistance between contacts - 2 and 4 -.

• Sensor at lower stop: 273 to 277 ohms.

• Sensor at upper stop: Maximum 67 ohms.

- Connect the multimeter to measure the resistance between contacts - 2 and 6 -.

• Sensor at lower stop: 63 to 67 ohms.

• Sensor at upper stop: Lowest 273 ohms.

- Connect the multimeter to measure the resistance between contacts - 4 and 6 -.

• Any sensor position: 335 to 345 ohms.

• The fuel tank must be filled completely in order to get an exact reading of the resistance on the "sensor on the upper stop" 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 an open circuit in the wiring.

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

Checking Fuel Level Sensor 2 when it is Removed






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

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

• Sensor at lower stop: approximately 289 ohms.

• Sensor at upper stop: approximately 50 ohms.

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

• Sensor at lower stop: approximately 51.1 ohms.

• Sensor at upper stop: approximately 292 ohms.

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

• Any sensor position: 335 to 345 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 the fuel level sensor 2 (G169). Refer to => [ Fuel Level Sensor 2 (G169) ] Fuel Level Sensor 2 (G169)