Fuel Gauge Sender: Testing and Inspection

Checking Sender For Fuel Gauge

Troubleshooting - (Part 1 Of 4):

Troubleshooting - (Part 2 Of 4):

Troubleshooting - (Part 3 Of 4):

Troubleshooting - (Part 4 Of 4):

Required for troubleshooting:
^ Multimeter Fluke 83
^ Connector Test Kit VW1594
^ Instrument Gauge Tester VW1301
^ Valid wiring diagram

Prerequisite:

^ S15 Fuse 15 (10A) OK!
^ Adjustment of the fuel gauge not possible (using the Scan Tool (ST))


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


Preparation:
- Remove luggage compartment floor cover.

Troubleshooting procedure:
- Perform test steps according to table
- If specified value/test result is obtained, proceed to next step (test result OK !)
- If specified value/test result is not obtained, use table for troubleshooting and repair
- Use valid wiring diagram for wire testing
- Disconnect test leads after each step

If malfunction has not been eliminated after performing all steps, check wiring of fuel gauge senders from Connector T4e, Terminal 2 to Connector T4e, Terminal 3, according to wiring diagram!

After repairing malfunction, perform adjustment of the fuel gauge.


NOTE: The wiring of the fuel gauge senders is partly located inside the fuel-tank. It can only be checked after removing the fuel gauge senders from the fuel-tank. The terminals of the connectors of the fuel gauge senders are not always directly connected to the fuel gauge senders. In some cases they are connected to the cabling inside the fuel tank.


WARNING!

When working on an open fuel system:

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

^ Before removing or installing senders for fuel gauge, locate the suction pipe of a workshop exhaust system near the fuel tank opening to remove fuel vapors. If no exhaust system is available use a radial fan (motor must be located outside the air flow) with a volume of at least 15 cubic meter/hrs (9 cfm).

^ Wear fuel resistant gloves whenever working on open fuel system.