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Thread: Allroad 2.5tdi Low Fuel Level Sensor (G210)

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  1. Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    Hi all, just spent the last 6 hours after towing the car home trying to solve whats up with it, can any one help & shed some light:

    Its my 2000 Allroad AKE:
    since December I have run out of diesel twice, low fuel warning on the dash had come on around 35miles left and it was dead at 20 miles left both times, I just though its a bit unussual but my own fault for going so low on fuel, so since then i have been weary monitoring the fuel guage vrs mileage left and carried a spare can in the boot, anyway
    so today driving home, car full to the roof with stuff, I noted I need to get diesel approx 50 miles left, no fuel light on, nearly at the garage and the glow plug light starts to flash, strange I though, may be the brake light switch and head to the garage car running ok, stop to fill it up, and then the car would not start sitting at the pump, turns over but not starting, tried a few things, but thought it need the codes read, so get towed home, get VCDS on it and the only code I get:

    01441 - Low Fuel Level Sensor (G210)
    27-00 - Implausible Signal

    aftersome reading up I get an ohmeter on the the g210 level sender and I get 450ohms dead on, this is good, so mess about with a few things learning how it all works. Pump in the tank runs fine on cranking, realised the pump doesn't push to the fuel filter. Codes cleared nothing comes back and so last resort crack open a few fuel lines to injectors, a lot of cranking until diesel starts coming out and eventually it fires, great, but why wouldn't it start at the garage?, the car was only off for 2-3mins max when filling up.

    My questions: Can this G210 sensor actually stop the car from starting??

    after it started at home I removed the plug to the G210 sensor & I get the flashing glow plug, i stopped the car, trying to simulate my earlier scenario but it starts again ok with an open circuit on G210??? can an implausable signal on this level sensor actually stop the car firing??

    any ideas as I am sure i didn't run out of diesel, but am keen to find a resolution to what i think may have been the issues before and it may be a recurring problem?

    can I change just this sensor if need be?

    any ideas, experiences and solutions greatly welcomed

    Andy
    ------------------------------------------
    2001 Audi A4 Saloon 2.0
    2000 Audi Allroad 2.5TDI V6 quattro
    Fully licenced Ross-Tech VCDS Interface
    Air Suspension Compressor Repair Kits: www.bagpipingandy.com
     
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  2. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    When faced with that fault code, without GFF to guide you through, all you can do is replace the fuel pump unit 4B0 906 087 BC and see what happens. This is available after market if you can find someone who sells Meat & Doria or Hoffa.
    Anthropogenic climate change, the biggest con inflicted on mankind since religion...

    Slava Ukraini
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  3. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    Thanks for the reply crasher, some more Q's

    If the baffle housing runs out of diesel will it give the fault "implausable signal"? or would it give a low level error?
    i'm trying to figure out if the g210 sensor is faulty or if the baffle housing has actually run out of diesel,

    Also Can the g210 sensor prevent the car starting?

    Any info welcomed

    Andy

    Ps what is GFF to guide through.
    ------------------------------------------
    2001 Audi A4 Saloon 2.0
    2000 Audi Allroad 2.5TDI V6 quattro
    Fully licenced Ross-Tech VCDS Interface
    Air Suspension Compressor Repair Kits: www.bagpipingandy.com
     
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  4. #4
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    GFF=guided fault finding

    Sent from my GT-I9100 using Tapatalk
    A4 2.5 tdi QS (mapped)


     
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  5. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    yes, sorry, Guided Fault Finding. VAG took away all of the fault code info on the AKE engine and made it all GFF applicable so I use VAS PC to work with problems like this.
    Anthropogenic climate change, the biggest con inflicted on mankind since religion...

    Slava Ukraini
    !


     
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  6. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    The answer I believe is yes as it happened to my Allroad after one of the fuel level sensors was incorrectly fitted by my indie mechanic. There are 3 sensors in all on the Allroad as it has a 'saddlebag' tank - so you'll need to check them all.

    I was driving home over Christmas on motorway at night with what I thought was a quarter tank - glow plug comes on, no low fuel warning, car limps to a stop and will not start at all. Starter motor turns but no firing (no fuel). Recovered on truck.

    Turns out the new sensor had been put in 180deg the wrong way round. This I assume sent an incorrect signal and fuel gauge gave faulty reading but ECU could not resolve the lack of fuel being drawn through the fuel pump (I assume) and shuts everything down. Slightly different to your story as you hadn't run out of fuel but the sensor implied that you had - again couldn't be resolved by ECU so perhaps it's to save potential damage.

    Anyway - sensor was correctly fitted and car fired up no problem (with some fuel added!).
     
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  7. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    can the intank pump assembly be removed without the special tool to undo the bayonet style fitment?

    I might have a look in there to make sure it is clean and all hoses are intact, check all level sensors resistance too. best price for a new unit is £260 from Audi dealer,

    it seems to run fine when tank is full but I will monitor it when around the 1/4 mark & nearer empty, makes me think it is not the g210 sensor but the baffle housing actually running out of fuel at a certain level, or levels are wrong , the joys of motoring,

    any tips on bleeding the system too for if and when it happens again?? the manual states basically to run the pump and remove return line at fuel injector pump but if the in tank pump doesn't pump forward how does it move the fuel up to the injector pump??

    regards

    Andy
    ------------------------------------------
    2001 Audi A4 Saloon 2.0
    2000 Audi Allroad 2.5TDI V6 quattro
    Fully licenced Ross-Tech VCDS Interface
    Air Suspension Compressor Repair Kits: www.bagpipingandy.com
     
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  8. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    You mention manual so it shows the tool for removing the pump. Are you aware of the suction-jet pump set up. Regards Peter
     
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  9. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    Yes Peter, i recon its ok as I get past 1/2 tank ok, but when I open it up I will have a look at it to see if fuel is drawn over by it, do i need the special tool to remove the pump housing or can i make do,

    regards

    Andy
    ------------------------------------------
    2001 Audi A4 Saloon 2.0
    2000 Audi Allroad 2.5TDI V6 quattro
    Fully licenced Ross-Tech VCDS Interface
    Air Suspension Compressor Repair Kits: www.bagpipingandy.com
     
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  10. Re: Allroad 2.5tdi Low Fuel Level Sensor (G210) 
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    Access is an issue without the tool. I have used a strap wrench on some retaining rings on other cars. Remember to renew the seal. The problem does not kick in until less than 1/3 of a tank and if you corner hard to the left then fuel flows across and the problem does not cut in until 1/4 of a tank. What manual do you have. ? Regards Peter
     
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