Fuel Level Sensor 3 -G237-, Checking

Special Tools And Workshop Equipment Required

Analog/Digital Multimeter FLU 83III
Connector Test Set VAG 1594D
Window Cutter VAG 1561A
Window Cutter - L Blade (2 pc.) VAG 1561/22
Scissors

Check Fuel Level Sensor 3 -G237- when it is Installed.

NOTE:

The fuel tank must be filled completely in order to have an exact reading of the resistance on the "Fuel tank full" when it is installed. Drive at least 500 meters (546 yards) after filling the fuel tank full to get rid of any bubbles in the fuel tank. Then fill the fuel tank again.

Check the Fuel Level Sensor 3 -G237- on the Fuel Level Sensor 2 -G169- sealing flange.

-- Move the left front seat all the way forward.

-- Remove the rear bench seat or left rear single seat, refer to Rear Seats .

-- Cut the insulation mat near the sealing flange cover (in direction of travel on the left side under the rear seat) with scissors along the perforation and fold to the side.

-- Cut through the adhesive rings all the way around the sealing flange cover using Window Cutter VAG 1561A and Window Cutter - L Blade (2 pc.) VAG 1561/22.

Fig 1: Cut Through Sealing Around Locking Flange Cover With VAG 1561A And VAG 1561/22

Courtesy of AUDI OF AMERICA, LLC

-- Remove the sealing flange cover.

-- Repair any damaged painted surfaces.

-- Apply corrosion protection if necessary.

-- Release the connector safety catch, and disconnect the connector -1- on the sealing flange.

Fig 2: Identifying Sealing Flange Connector

Courtesy of AUDI OF AMERICA, LLC

-- Connect the multimeter for resistance measurements shown in the table.

Fig 3: Fuel Level Sensor Connector Terminal Identification

Courtesy of AUDI OF AMERICA, LLC

Measurement at Contact	Tank Empty	Tank Full
1 + 3	approximately 273.8 Ω	approximately 63.9 Ω
1 + 5	approximately 63.9 Ω	approximately 273.8 Ω
3 + 5 ¹⁾	approximately 337 Ω	approximately 337 Ω
¹⁾ Arbitrary sensor position

Check Fuel Level Sensor 3 -G237- once it is Removed.

Fig 4: Fuel Level Sensor 3 Connector Terminal Identification

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To check resistance values "tank full" or "tank empty", the fuel level sensor must be removed, refer to FUEL LEVEL SENSOR 3 -G237-, REMOVING AND INSTALLING , and the sensor floater must be moved to the upper or lower stop.

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

-- Connect the multimeter for resistance measurements shown in the table.

Measurement at Contact	Tank Empty	Tank Full
1 + 2	approximately 289 Ω	approximately 50.1 Ω
1 + 3	approximately 51.6 Ω	approximately 289 Ω
2 + 3 ¹⁾	approximately 337 Ω	approximately 337 Ω
¹⁾ Arbitrary sensor position

The Fuel Level Sensor 3 -G237- is faulty if the following is found:

Large deviations in measured values
Measured value 0 Ω (short circuit).
Measured value ∞ Ω (open circuit).
No fault in the electric wires.

-- Install the Fuel Level Sensor 3 -G237-, refer to FUEL LEVEL SENSOR 3 -G237-, REMOVING AND INSTALLING .