Checking fuel gauge G sender (CAYA, CAYB, CAYC): VW 1.6 TDI (CAYA, CAYB, CAYC)

Checking fuel gauge
G
sender (CAYA, CAYB, CAYC)
Special tools and workshop equipment required
Hand-held multimeter
V.A.G 1526D
Auxiliary measuring set
V.A.G 1594C
Removal wedge
3409
Procedure
Fold front right seat forwards as far as possible.
Remove rear bench seat
Rep. gr.
72
Unclip cover
1
for flange at retaining tabs
arrows
, using
removal wedge
3409
.
Carefully detach electrical connector from flange
1
, releasing the connector catches to do so.
Fuel gauge sender
G
installed:
Connect multimeter between contacts
2
and
3
in order to measure resistance.
Sender at lower stop: 266 … 274 Ω.
Sender at upper stop: 67 … 73 Ω.
Connect multimeter between contacts
2
and
4
in order to measure resistance.
Sender at lower stop: 67 … 73 Ω.
Sender at upper stop: 266 … 274 Ω.
Connect multimeter between contacts
3
and
4
in order to measure resistance.
Any sender position: 335 … 345 Ω.
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.
To test the maximum and minimum resistance values for
“fuel tank full”
and
“fuel tank empty”
, remove the fuel delivery unit and move the sender float all the way to its top or bottom position.
The following values are obtained with the fuel delivery unit removed, due to the greater travel of the float arm:
Fuel gauge sender
G
removed:
Connect multimeter between contacts
2
and
3
in order to measure resistance.
Sender at lower stop: 285 … 295 Ω.
Sender at upper stop: 48 … 52 Ω.
Connect multimeter between contacts
2
and
4
in order to measure resistance.
Sender at lower stop: 48 … 52 Ω.
Sender at upper stop: 285 … 295 Ω.
Connect multimeter between contacts
3
and
4
in order to measure resistance.
Any sender position: 335 … 345 Ω.
If a large deviation in values is recorded or if a measured value of 0 Ω (short circuit) or of ∞ Ω (open circuit) is recorded and if no faults have been detected in the electrical wiring and cables, renew
fuel gauge sender
G
.
Remove and install
fuel gauge sender
G
Chapter
.