2014 Passat TDI Fuel Gauge Issues

   #1  

Avetisov22

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Hey everyone,

I hope and pray this is the LAST TIME in a LONG TIME I am asking for help with my car. I have a 2014 VW Passat TDI SEL. My car is a salvaged title that sustained very minor frontal damage (broken tabs on headlights, cracked bumper and plastics, radiator was clipped just enough to warrant replacement. Engine, transmission, frame, etc were unaffected. Took me a mere 3 weeks to disassemble, order replacement parts, and reassemble myself in my garage.

Unfortunately, the battery was bad. I attempted to jump start the car but to no avail. Battery was replaced. Only electric issues I had/ have: amplifier was replaced, speakers work excellent now, trunk release switch was replaced on driver door, and the sensor for "hood open" seems to not work (which ill replace later), and the airbag passenger seat module was replaced and coded (as per my last post). The one issue with the vehicle that I cant seem to figure out is my fuel gauge. When I fill the car to FULL, it doesnt reach full. Stops about 90% of the way there. After reading some posts online, I opted to replace the fuel sender unit. Got a genuine one from my VW dealer and installed it. Initially, the issue was solved. Appoximately 5 ignition cycles later (and only 5 miles on the ODO since fill up, the need dropped to 85%. Refueling the vehicle will not bring it back to full.

I found other threads that speak of recalibration (draining tank, filling 2.5L, calibrating reserve under INSTRUMENTS, ADAPTATION, and calibrating fuel gauge. However, before I do this, I want to make sure this will indeed fix the issue (if anyone has experience with this). I got the car up on stands and checked wiring integrity, found nothing. I only got 1 code from the fuel sender in VCDS which read HIGH RESISTANCE, but this was around the time I swapped the 2 out. I have no idea if the code was from the new one or old one. Like an idiot I didnt think to check first or disconnect the battery.

Dealer told this morning that recalibration should not be necessary and that I should give it some time and drive it around to let it "settle in" but I am having my doubts.

My thoughts at the moment are:

1) replacement fuel sender could be faulty
2) replacement sender could be inside the tank incorrectly? (points approximately NorthWest inside the tank, as i found the old sender in this position).
3) replacement sender needs to be calibrated
4) gauge cluster could be bad after battery died and subsequent attempts to jump?

Any help with this would be greatly appreciated!!

Here is a full scan done this morning for reference:

Code:
Saturday,03,December,2022,13:20:29:61775
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 22.10.0.1 (x64)  HEX-V2 CB: 0.4623.4
Data version: 20221026 DS344.0
www.Ross-Tech.com


VIN: 1VWCN7A30EC029565   License Plate:
Mileage: 97880km-60819mi   Repair Order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: A3-VW41 (7N0)
Scan: 01 02 03 05 08 09 15 16 17 19 25 2B 2E 36 37 42 44 46 47 4F
          52 56 62 72 75 77

VIN: 1VWCN7A30EC029565   Mileage: 97880km-60819miles

01-Engine -- Status: OK 0000
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
05-Acc/Start Auth. -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
2B-Steer. Col. Lock -- Status: OK 0000
2E-Media Player 3 -- Status: OK 0000
36-Seat Mem. Drvr -- Status: OK 0000
37-Navigation -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
47-Sound System -- Status: OK 0000
4F-Centr. Electr. II -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
75-Telematics -- Status: OK 0000
77-Telephone -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CKRA)       Labels:. 03L-906-022-CFC.clb
   Part No SW: 03L 997 009 J    HW: 03L 907 309 S
   Component: R4 2.0l TDI   H24 9982
   Revision: 71H24---    Serial number:                CVN: D240C61FD45710C1
   Coding: 001D0012042400008000
   Shop #: WSC 00023 444 00000
   ASAM Dataset: EV_ECM20TDI01103L997009J 004005
   ROD: EV_ECM20TDI01103L997009J.rod
   VCID: 3B233BD703EAB423FE0-806E
   VINID: 0669D37874430154C0089146146CEF1DD7

No fault code found.
Readiness: 0 0 0 0 1

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 02E-927-770.clb
   Part No SW: 02E 300 062 B    HW: 02E 927 770 AL
   Component: GSG DSG AG6     521 9437
   Revision: 05652104    Serial number: 00001307040358
   Coding: 0000020
   Shop #: WSC 09003 957 00200
   VCID: 1471B06B42749B5B5FA-8040

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 1K0-907-379-60EC1F.clb
   Part No SW: 1K0 907 379 BL    HW: 1K0 907 379 BL
   Component: ESP MK60EC1   H31 0152
   Revision: 00H31001  
   Coding: C54BC0F549240003A31003EA921E0042A71000
   Shop #: WSC 09003 957 00200
   VCID: 7DA7F5CF5DFE7A13804-8028

No fault code found.

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. (J518)       Labels:| 5K0-959-434.clb
   Part No SW: 5K0 959 434 B    HW: 5K0 959 434
   Component: VWKESSYPQ35GP 086 1101
   Revision: 00086000    Serial number: 0193938492
   Coding: 130C0C
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_KESSYPQ35G A02013
   ROD: EV_KESSYPQ35G_A02_VW31.rod
   VCID: 343110EB2EB47B5B3FA-8060

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels:| 5K0-907-044.clb
   Part No SW: 561 907 044 AB    HW: 561 907 044 AB
   Component: Climatronic   H03 0505
   Revision: 00001K01  
   Coding: 0030019012
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_ACClimaBHBVW411 A01001
   ROD: EV_ACClimaBHBVW411_VW41.rod
   VCID: 57EB87679F827043FA8-8002

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 1K0-937-08x-09.clb
   Part No SW: 5K0 937 087 AE    HW: 5K0 937 087 AE
   Component: BCM PQ35 H+   122 0173
   Revision: BL122001  
   Coding: EF200E1B982B08D4098802013600854800F1A086458015B064806000BC70
   Shop #: WSC 09003 957 00200
   VCID: 78A9E4DB72DC5F3BD32-802C

1 Fault Found:
01500 - Bulb for Fog-Lamps; Right (L23)
            010 - Open or Short to Plus
             Freeze Frame:
                    Fault Status: 01101010
                    Fault Priority: 4
                    Fault Frequency: 8
                    Reset counter: 213
                    Mileage: 97847 km
                    Time Indication: 0
                    Date: 2017.04.24
                    Time: 13:46:10

             Freeze Frame:
                        Term 15 On
                    Voltage: 12.10 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF


-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5K0-959-655.clb
   Part No SW: 5C0 959 655 AE    HW: 5C0 959 655 AE
   Component: AirbagVW10G   014 0851
   Serial number: 003MWM02NBTF
   Coding: 00005033
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_AirbaVW10SMEVW360 001026
   ROD: EV_AirbaVW10SMEVW360.rod
   VCID: 75B7EDEF654E2253C84-8020

   Seat occupied recognition:
   Subsystem 1 - Part No SW: 5C6 959 339 B    HW: 5C6 959 339 B
   Component: BF-Gewichtss.  H10 0046
   Serial number: 6940000Y210001ZB3W09
   Coding: 303044

   Crash sensor for side airbag: driver side:
   Subsystem 2 - Part No SW: 5K0 959 354     HW: 5K0 959 354
   Component: S.Sens.Fahr.V  H02 ----
   Serial number: 3572MSME2341227DZZZR

   Front Passenger's Side Airbag Crash Sensor:
   Subsystem 3 - Part No SW: 5K0 959 354     HW: 5K0 959 354
   Component: S.Sens.Beif.V  H02 ----
   Serial number: 3582MSME3B24227DZZZ

   Rear Side Airbag Crash Sensor (on driver's side):
   Subsystem 4 - Part No SW: 5K0 959 351 A    HW: 5K0 959 351 A
   Component: S.Sens.Fahr.H  H02 ----
   Serial number: 3516KSME40624925ZZZL

   Passenger side rear thorax airbag crash sensor:
   Subsystem 5 - Part No SW: 5K0 959 351 A    HW: 5K0 959 351 A
   Component: S.Sens.Beif.H  H02 ----
   Serial number: 3526KSME154C5625ZZZU

   Crash sensor for front airbag: driver side:
   Subsystem 6 - Part No SW: 5K0 959 659 A    HW: 5K0 959 659 A
   Component: F.Sens.Fahr  H02 ----
   Serial number: 3556LSME6A406526ZZZX

   Crash sensor for front airbag: front passenger side:
   Subsystem 7 - Part No SW: 5K0 959 659 A    HW: 5K0 959 659 A
   Component: F.Sens.Beif  H02 ----
   Serial number: 3566LSME385A7926ZZZ2

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:| 5K0-953-569.clb
   Part No SW: 1K5 953 521 AR    HW: 5K0 953 569 E
   Component: LENKS.MODUL   016 0140
   Revision: FF010042    Serial number: 20130712201512
   Coding: 000A140000
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_SMLSNGVOLWSXS A01004
   ROD: EV_SMLSNGVOLWS.rod
   VCID: 7DA7F5CF5D7E7A13804-8028

   Multifunction steering wheel control module:
   Subsystem 1 - Part No SW: 3C8 959 537 D    HW: 3C8 959 537 D  Labels: 3C8-959-537.CLB
   Component: E221__MFL-YVJ  H07 0022
   Coding: E30000

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-XXX-17.clb-SRI1
   Part No SW: 561 920 970 G    HW: 561 920 970 G
   Component: KOMBI         H04 0811
   Serial number: 00000000000000
   Coding: 231E01
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04721
   ROD: EV_Kombi_UDS_VDD_RM09_004_VW36.rod
   VCID: 1E65D243B038C10BF9E-804A

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 7N0-907-530-V2.clb
   Part No SW: 7N0 907 530 AM    HW: 7N0 907 530 AM
   Component: J533  Gateway H55 1642
   Revision:   H55       Serial number: 24081303000048
   Coding: 461000
   Shop #: WSC 09003 957 00200
   VCID: 7BA3FBD743EA7423BE0-802E

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels:| 5K0-920-xxx-25.clb
   Part No SW: 5K0 953 234     HW: 5K0 953 234
   Component: IMMO          H04 0811
   Serial number:             
   Coding: 000007
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03710
   ROD: EV_Immo_UDS_VDD_RM09_VW21.rod
   VCID: 6A8DCE933CF0FDAB556-803E

No fault code found.

-------------------------------------------------------------------------------
Address 2B: Steer. Col. Lock (J764)       Labels:* 5K0-905-861.clb
   Part No SW: 5K0 905 861 C    HW: 5K0 905 861 C
   Component: ELV-PQ35      H21 0240
   Revision: 00000000    Serial number: 13000100346003
   Coding: 4900000000000000
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_ELVMarquMPVW36X A01001
   ROD: EV_ELVMarquMPVW36X.rod
   VCID: 30391CFBDAAC477B5B2-8064

No fault code found.

-------------------------------------------------------------------------------
Address 2E: Media Player 3
Cannot be reached

-------------------------------------------------------------------------------
Address 36: Seat Mem. Drvr (J136)       Labels: None
   Part No SW: 561 959 760 B    HW: 561 959 760 B
   Component: MEM-FS        H04 0182
   Revision: AA000000    Serial number: 00000070069643
   Coding: 00581B0000000000000021010100202020202120202020
   Shop #: WSC 09003 957 00200
   VCID: 221DE6B384C0E5EBDD6-8076

No fault code found.

-------------------------------------------------------------------------------
Address 37: Navigation (J0506)       Labels:. 1T0-035-680.clb
   Part No SW: 3C0 035 684 J    HW: 3C0 035 684 G
   Component: RNS-MID       H03 4366
   Revision: AB001001    Serial number: VWZ6Z7N5080077
   Coding: 04090042010000A6000B
   Shop #: WSC 09003 957 00200
   VCID: 2A0D0E93FCF03DAB956-807E

   Subsystem 1 - Part No: 7L6 919 859
   Component: NAR V6  7963

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386)       Labels:| 3C0-959-70X-GEN4.clb
   Part No SW: 561 959 701 A    HW: 3C0 959 793 C
   Component: TUER-SG FT    002 0525
   Revision: 12110009    Serial number: 0007265878
   Coding: 0405FD
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_TSGFPQ25BRFVW46X A04001
   ROD: EV_TSGFPQ25BRFVW46X.rod
   VCID: 1C61D84BA624D31B17A-8048

   Slave Driver:
   Subsystem 1 - Part No SW: 561 959 811 B    HW: 561 959 811 B  Labels: 1K0-959-70X-GEN4.CLB
   Component: J388__TSG_HL  006 5470
   Serial number: 14202630130903084916
   Coding: 800000

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1K0-909-14x-GEN3.clb
   Part No: 1K0 909 144 R
   Component: EPS_ZFLS Kl. 290    3501
   Revision: 00H22000  
   Shop #: WSC 01357 011 00200
   VCID: 392F21DF05568633ECC-806C

No fault code found.

-------------------------------------------------------------------------------
Address 47: Sound System (R12)       Labels: 5K0-035-456.clb
   Part No SW: 5C6 035 456 A    HW: 5C6 035 456 A
   Component: KonzernAmp10K H07 6813
   Revision: --------    Serial number: EAA098A0098608
   ASAM Dataset: EV_AudioVerst10KanalSTT3 S01001
   ROD: EV_AudioVerst10KanalSTT3_VW36.rod
   VCID: 2615FAA3E86819CBB1E-8072

No fault code found.

-------------------------------------------------------------------------------
Address 4F: Centr. Electr. II (J520)       Labels:. 1K0-907-532.clb
   Part No SW: 7N0 907 532     HW: 7N0 907 530 AM
   Component: EZE_2         H55 1642
   Revision:   H55       Serial number: 24081303000048
   Coding: 01030108
   Shop #: WSC 09003 957 00200
   VCID: 6FBBDF8707921883028-803A

   Subsystem 1 - Part No SW: 561 959 591     HW: 561 959 591
   Component: J245 P05 FFD7  H07 0004
   Serial number: 53388786011311600258
   Coding: 181100

   Subsystem 2 - Part No SW: 561 919 204 B    HW: 561 919 204 B
   Component: Analoguhr  008 0005

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387)       Labels:| 3C0-959-70X-GEN4.clb
   Part No SW: 561 959 702 A    HW: 3C0 959 792 C
   Component: TUER-SG BT    002 0525
   Revision: 14110009    Serial number: 0007257879
   Coding: 0405FC
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_TSGBPQ25BRFVW46X A04001
   ROD: EV_TSGBPQ25BRFVW46X.rod
   VCID: 1D67D54FBD3EDA13E04-8048

   Slave Passenger:
   Subsystem 1 - Part No SW: 561 959 812 B    HW: 561 959 812 B  Labels: 1K0-959-70X-GEN4.CLB
   Component: J389__TSG_HR  006 5470
   Serial number: 14202631130903101628
   Coding: 800000

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio (J0506)       Labels:. 1T0-035-680.clb
   Part No SW: 3C0 035 684 J    HW: 3C0 035 684 G
   Component: RNS-MID       H03 4366
   Revision: AB001001    Serial number: VWZ6Z7N5080077
   Coding: 04090042010000A6000B
   Shop #: WSC 09003 957 00200
   VCID: 2A0D0E93FCF03DAB956-807E

   Subsystem 1 - Part No: 7L6 919 859
   Component: NAR V6  7963

No fault code found.

-------------------------------------------------------------------------------
Address 75: Telematics (J949)       Labels:| 12E-035-284.clb
   Part No SW: 561 035 285     HW: 561 035 285
   Component: OCULowUSA     014 0086
   Serial number: 000003554140505
   Coding: 02140102C2423A007F1606000000
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_OCULow 001010
   ROD: EV_OCULow_001.rod
   VCID: 53F373778B7A5C63060-8006

1 Fault Found:
2103041 - Control Module
          B1788 F0 [009] - Start Prohibition Deactivated
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 8
                    Fault Frequency: 1
                    Reset counter: 213
                    Mileage: 97882 km
                    Date: 2022.12.03
                    Time: 13:19:51


-------------------------------------------------------------------------------
Address 77: Telephone (J412)       Labels:| 5N0-035-729.clb
   Part No SW: 5N0 035 729 A    HW: 5N0 035 729 A
   Component: TELEFON       H05 0315
   Revision: 1B001001    Serial number: 00007664920309
   Coding: 0A10030080010110
   Shop #: WSC 09003 957 00200
   ASAM Dataset: EV_UHVUMI 001007
   ROD: EV_UHVUMI.rod
   VCID: 2E050283C098518B49E-807A

No fault code found.

End----------(Elapsed Time: 01:19, VBatt start/end: 12.1V/12.1V)-----------
 
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   #2  

Jef

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I would agree with the dealer, shouldn't need to do a calibration. Looking at the factory repair manual based on the VIN, there is nothing about calibration when installing a fuel level sensor. There is this note:

Be careful not to bend the fuel gauge sensor when installing the fuel delivery unit.

I'm not finding any documentation on what kind of Ohm values you should expect from the gauge and upper and lower stops. Verify the 3 wires from the instrument cluster to the level sensor are to factory design.

If you like the smell of diesel, then pull the level sensor out and most it to "full tank" position and then turn the ignition on and see if it then registers a full tank in the gauge.

If you want the quickest and laziest test, do an Output Test on the instrument cluster and verify it can operate the analog needles correctly. Drop to lowest value, sweep to highest value, sweep to lowest value, sweep to middle value.
 
   #3  

Jetta 97

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4) gauge cluster could be bad after battery died and subsequent attempts to jump?
^^^^^^This is Possible ,
but first try as Jef suggested Output Test on the instrument cluster and see is it gauge goes all way to full .
you can also try to Adjust fuel gauge in Adaptation, look for fuel tank curve or something like that .
 
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   #4  

Avetisov22

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I would agree with the dealer, shouldn't need to do a calibration. Looking at the factory repair manual based on the VIN, there is nothing about calibration when installing a fuel level sensor. There is this note:



I'm not finding any documentation on what kind of Ohm values you should expect from the gauge and upper and lower stops. Verify the 3 wires from the instrument cluster to the level sensor are to factory design.

If you like the smell of diesel, then pull the level sensor out and most it to "full tank" position and then turn the ignition on and see if it then registers a full tank in the gauge.

If you want the quickest and laziest test, do an Output Test on the instrument cluster and verify it can operate the analog needles correctly. Drop to lowest value, sweep to highest value, sweep to lowest value, sweep to middle value.
I’m gonna drive a bit and let the level go down before I recheck the sender again, don’t want diesel going everywhere. Output tests do indeed pass with the gauge going to full no problem. I can get the needle to full by changing the adaptation to +10 on the fuel gauge, but it makes me wonder if it’s even accurate at that point or not. I reverted it back for the time being.
 
   #5  

Avetisov22

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^^^^^^This is Possible ,
but first try as Jef suggested Output Test on the instrument cluster and see is it gauge goes all way to full .
you can also try to Adjust fuel gauge in Adaptation, look for fuel tank curve or something like that .
output tests passed. Anyone know how difficult it is to take the gauge cluster off? Lol.
 
   #6  

Avetisov22

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Ok, so I took the sender out of the tank again. With it plugged in and moving it up, the fuel gauge does indeed register FULL and goes to zero when I release it. Reinstallation yielded same reading as before. Just filled it up again and it stopped at the marking prior to the FULL mark. VCDS shows fuel sensor at 81 ohm, fuel level at 63.5L, Fuel gauge needle position at 261.1 degrees. 3.1 gallons went in and it was a hair below 3/4 prior to refill.
 
   #8  

Avetisov22

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That is Normal. 3.1 gallons is not small about of fuel .
I agree, but gauge still refuses to go to full. I’m thinking, maybe I should replace the lift pump along with the sender to rule out any malfunctions there.
 
   #9  

Jef

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With it plugged in and moving it up, the fuel gauge does indeed register FULL

What would be the ohm value for full when out of the tank? Could it be hanging up inside the take and not floating to the full position?

PL24 shows part number 3AA 919 050 L for a complete drop in tank unit (pump / sensor) and part number 3AA 919 673 for the sensor only. Does this match up to what you got?

while you are hung up on how good it shows a full tank... how good it is showing an empty tank? I'd be more concerned about how good is the reading when it is low on fuel. If the gauge is off on a full tank... what is the harm beyond annoying? But if the gauge isn't so great on the low side, it could give a false confidence one could put off a refill a bit longer.
 
   #10  

Avetisov22

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What would be the ohm value for full when out of the tank? Could it be hanging up inside the take and not floating to the full position?

PL24 shows part number 3AA 919 050 L for a complete drop in tank unit (pump / sensor) and part number 3AA 919 673 for the sensor only. Does this match up to what you got?

while you are hung up on how good it shows a full tank... how good it is showing an empty tank? I'd be more concerned about how good is the reading when it is low on fuel. If the gauge is off on a full tank... what is the harm beyond annoying? But if the gauge isn't so great on the low side, it could give a false confidence one could put off a refill a bit longer.
Those appear to be the correct part numbers, ive been going off of those. I was under the impression that the sensor was the issue at play so i replaced it and it didnt fix the issue. I found a new pump for sale as I thought maybe it could the issue. VCDS shows 81 ohm with the replacement sensor.

To my suprise, the pump arrived today and i had a new sensor included with it! After much debate in my head, I opted to install the unit in its entirety as it arrived (instead of swapping the new sensor i bought the first time around onto the new pump and attempting to return the unused one to the dealer). Initially, after installation, with appox 5.5 gallons missing (knew this after i went for a fill up) the gauge quickly read FULL, which i knew wasnt the case. Went and filled up the car and its displaying full. No adjustments on adaption needed. Gonna monitor is over the next week now to see how is behaves.

Now i just need to persuade VW to at least take back the sensor i already tried out lol. Wish me luck!
 
   #11  

EuroX

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Northern NJ USA
VCDS Serial number
C?ID=208579
A gauge sweep will tell you if you have an issue with a cluster. In regards to resistance readings, readings change go up normally with temperature. I would check the gauge with the sender connected and move by hand and watch the dash see if it does in deed to go full and empty. Also VCDS can pull up those MVB and tell what the sender is reading resistance wise. Also this vehicle may have more than 1 sender. I would be checking resistance on both if both senders are present. It wouldn't hurt to compare VCDS resistance readings to actual readings taken with a DVOM. If it determined that fuel sender is ok I would be checking wiring from sender to dash or wherever it runs and checking resistance for those wires. Normally anything higher than 0.3ohms is not good but that depends on thickness and length of wire also.

I would also make sure that the sender is being installed in the correct orientation and that no wires/hoses inside the tank are preventing the sender and float from moving freely.
 
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