Checking fuel gauge sender -G-

Special tools and workshop equipment required

Hand-held multimeter -V.A.G 1526C-

Auxiliary measuring set -V.A.G 1594C-

Procedure
– Remove rear seat bench → Rep. Gr.72.
– Unscrew cover for flange (right-side) -
arrows-.
– Unplug electrical connector -2- at flange.

Note
Disregard -item 1-.

– Connect hand-held multimeter -V.A.G

1526C- to measure resistance between
contacts -2- and -3-.

Sender installed Sender at lower Sender at

 stop upper stop
Fuel gauge sender -G-, - approx. 70 Ω approx. 270 Ω
G169-, -G237-

Note

If the resistance is 0 Ω, there is a short circuit. If the resistance
is ∞ Ω, there is an open circuit in the wiring.

The fuel gauge senders -G-, -G169- and -G237- are wired in
series; for this reason, the three senders are checked together
in this test.

To test one of the senders separately, remove the relevant
sender → Chapter, → Chapter or → Chapter.

In order to test the maximum and minimum resistance values
for “tank full” and “tank empty”, move the float of the sender all
the way to its top or bottom position.

If a malfunction is suspected, you can unplug electrical
connector on fuel gauge sender 2 -G169- and measure
resistance at unplugged connector in order to check
resistance of fuel gauge sender 3 -G237- (depending on fuel
level), while still installed.

The following values are obtained with the fuel gauge senders
removed, due to the greater travel of the float arm:
Versions up to approx. 02.1999

Sender removed Sender at lower Sender at

stop upper stop
Fuel gauge sender -G- approx. 10 Ω 1) approx. 70 Ω
Fuel gauge sender 2 - approx. 20 Ω approx. 118.5 Ω
G169-
Fuel gauge sender 3 - approx. 30 Ω approx. 81.5 Ω
G237-
 1)When installed, the resistance of the fuel gauge sender -
G- is approx. 20 Ω (tank empty).

Note
On versions up to approx. 02.1999, all three senders must be
replaced with the new type of senders if one of the fuel gauge
senders -G- is defective.
Versions from approx. 02.1999 onwards

Note
On versions from approx. 02.1999 onwards, the resistance range
of fuel gauge sender 2 -G169- and fuel gauge sender 3 -G237-
was altered. However, the overall resistance → Anchor is the
same as before.

Sender removed Sender at lower Sender at

stop upper stop
Fuel gauge sender -G- approx. 10 Ω 1) approx. 70 Ω
Fuel gauge sender 2 - approx. 20 Ω approx. 108.5 Ω
G169-
Fuel gauge sender 3 - approx. 30 Ω approx. 91.5 Ω
G237-
 1)When installed, the resistance of the fuel gauge sender -
G- is approx. 20 Ω (tank empty).