Fuel level gauge not working even though level sensor is fine

[dbetter]

I've taken these senders out three times now, with not much luck at repairing the issue. My fuel level 2 sensor on the driver side of my B6 A4 Quattro 1.8t, which is responsible for the instrument cluster gauge reading, is showing 55 ohms, which I am told is in range. Not sure why it's not going to full even with a full tank, tried using vcds to calibrate the tank, highest I can get it to go is 3/4 tank. Any help is appreciated, I've tried the fuse trick as well to try an reset it, no luck. I'll post my scan and a picture of my meter.
20190825_175934.jpg
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Address 17: Instruments Labels: 8E0-920-9xx-8E2.lbl
Part No: 8E0 920 950 HX
Component: KOMBI+WEGFAHRS. RB8 D29
Coding: 03200
Shop #: WSC 03354
VCID: 064092DB20CF657FA3-5184
WAULC58E02A135667 AUZ6Z0A0266150

7 Faults Found:
01039 - Coolant Temperature Sensor (G2)
30-10 - Open or Short to Plus - Intermittent
00771 - Fuel Level Sensor (G)
30-00 - Open or Short to Plus
00438 - Fuel Supply Sensor 2 (G169)
30-10 - Open or Short to Plus - Intermittent
00668 - Supply Voltage Terminal 30
53-10 - Supply Voltage Too Low - Intermittent
01331 - Door Control Module; Driver Side (J386)
49-10 - No Communications - Intermittent
01320 - Control Module for Climatronic (J255)
49-10 - No Communications - Intermittent
01304 - Radio
49-00 - No Communications

[EuroxS4]

What is the vin for the car where the cluster is installed. As according to your scan your showing a rb8 cluster in a 2002 vin. Not possible as rb8 was only installed in later a4/s4 2004 or 2005 model year only and some cabriolets.

Also both sensors report a ohms reading then the average is calculated not just 1 sender.

[dbetter]

Car vin is WAULC58E02A135667, I tested my passenger sender too, it was in range, I think 49 ohms, so do u think someone swapped my cluster??

[dbetter]

Recoded the soft coding in the module, it got rid of all my fault codes except for fuel level sensor (G), and my fuel gauge is reading 3/4 when I have a full tank

[EuroxS4]

have you tried doing the gauge sweep in vcds??

[dbetter]

Your not able to on the B6's, but I have done a full calibration which resets the cluster

[imnuts]

While the senders test ok, are they operating properly when installed? There's a thread around here on replacing the sender/fuel pump. Newer units have a small hose that needs to be put into the correct spot on installation or it causes fuel level issues. Could that be what's causing your issue, at least in part?

Also, have you checked the wiring that connects to the sender? There could be a break in the insulation somewhere causing your fault given the code you have.

Sent from my Pixel 3 XL

[old guy]

Clicky click®

[Nollywood]

Car vin is WAULC58E02A135667, I tested my passenger sender too, it was in range, I think 49 ohms, so do u think someone swapped my cluster??

Has this always been an issue since you had the car? Or did it occur in your ownership?

[dbetter]

Clicky click®

Hmmm, I didnt check the placement of my vent line when installing the pump, that could very well be my issue, I'll have to try it in a few days when my fuel level goes down far enough so I can pull the top off it. Also @Nollywood, I've had this issue since I bought the car, on July 15th of this year, so I haven't had it long.

[Turbo510]

There's a thread around here on replacing the sender/fuel pump. Newer units have a small hose that needs to be put into the correct spot on installation or it causes fuel level issues.

That's what tripped me up, the small overflow tube which should be fitting through a funnel-shaped opening in the tank's plastic support bracket. If left loose, the tube interferes with the float. My car would do the same thing with the fuel gauge; once I was aware of this issue, it was fixed in 10 minutes. Run your fuel down enough in the tank so the access cover can be removed without flooding the back seat area with gas, and check that little tube.

[EuroxS4]

Could be your issue if the float is getting hung up. This is why good repair information is important and knowing how its supposed to be routed.

- - - Updated - - -

Your not able to on the B6's, but I have done a full calibration which resets the cluster

B6's will go the gauge sweep all clusters will. Not at start up but rather output test of steppers to make sure they are operating correctly.

[shurur9]

Could be your issue if the float is getting hung up. This is why good repair information is important and knowing how its supposed to be routed.

- - - Updated - - -



B6's will go the gauge sweep all clusters will. Not at start up but rather output test of steppers to make sure they are operating correctly.

I think that I had the same problem and you helped me.
It was the tank type/volume setting being wrong somehow...probably done accidentally when I was setting some other feature in VCDS.

[dbetter]

Just fixed my vent tube, didnt't fix it, so I did the output tests, as well as full calibration in the Adaptation, and tried setting fuel level sensors to 160 in Adaptation as well, highest it will go at 160 is 3/4 full... Any other ideas?

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Address 17: Instruments Labels: 8E0-920-9xx-8E2.lbl
Control Module Part Number: 8E0 920 950 HX
Component and/or Version: KOMBI+WEGFAHRS. RB8 D29
Software Coding: 01231
Work Shop Code: WSC 03354
Additional Info: WAULC58E02A135667 AUZ6Z0A0266150
VCID: 064092DB20CF657FA3-5184
2 Faults Found:

00771 - Fuel Level Sensor (G)
30-00 - Open or Short to Plus
01304 - Radio
49-00 - No Communications

[EuroxS4]

Pull fuses 15 and 28. Try to start the car. It may start and stall. Turn igniton off then put fuses back in and see what the gauge reads. Also have you tried going into MVB 4 in the cluster to see what each sender is sending to the cluster??

[dbetter]

Fuel level sensor 1 readin 510 ohms..... sensor two is fine at 106 ohms, gonna check cluster wiring now.
20190903_194102.jpg

[EuroxS4]

Fuel level sensor 1 readin 510 ohms..... sensor two is fine at 106 ohms, gonna check cluster wiring now.
20190903_194102.jpg

According to that picture sensor one is no good. Resistance is too high.With a empty tank should be maxed out at 305ohms not 510. When full should be between 56 to 68ohms. I would say sender 1 is no good.fuel sensor.png

[dbetter]

The sensor is fine, I've tested both of them already, pulled my cluster out about 30 min ago, tested pins 32 and 3 of the blue connector, got no reading. Switched to pin 32 and 11, and got 112 ohms from my driver side sensor. So then I unplugged passenger side sensor and tested for continuity, one of the wires are fine, but one I got no continuity through. Gonna have to do some rewiring and I think I've found my issue