Jetta Hybrid Stalling Due to Faulty Fuel Sensor

Had a similar issue with my Passat GTE Hybrid about a year ago. The fuel gauge was showing incorrect readings and the car would stall at idle, classic symptoms of a fuel tank sensor fault. The car electronics were getting confused about the actual fuel level, triggering the check engine light and safety shutdowns. The main problem was the fuel level sensor unit inside the fuel tank. In my case, the sensor wiring had corroded due to moisture getting into the assembly. This is actually a known weak point in several VW hybrid models. The repair required dropping the fuel tank to replace the complete sending unit assembly. While this sounds complex, its not an uncommon repair for shops familiar with hybrids. The job typically takes 3-4 hours since they need to safely drain the tank, disconnect the hybrid system, and replace the sensor assembly. Its worth having it fixed properly as faulty readings can lead to more serious issues like fuel pump damage or getting stranded with an empty tank despite what the car dashboard shows. Make sure to mention the stalling symptom to the mechanic, this points directly to the sensor fault rather than just a display issue. Ask them to check the wiring connections before replacing the entire unit, as sometimes cleaning the contacts can resolve the problem.

Really appreciate your detailed response about the fuel tank sensor issue. Sounds exactly like what I am experiencing with my Jetta. The car stalling at idle is particularly worrying and based on your explanation about the sending unit assembly, I should probably get it checked soon. Since its been a while since your repair, wondering how much you ended up paying for the fix? Also curious if you have had any similar sensor fault issues since the repair was done? Just trying to budget properly and make sure this fix will actually solve the problem long term.

After bringing my Passat GTE to the mechanic, the fuel system issues were completely resolved. The fuel level sensor fault was traced to a blown fuse, which was a much simpler fix than initially expected. The total repair cost came to 52€ for replacing the defective fuse. Since the repair, the car dashboard has been displaying accurate fuel gauge readings and the stalling problems have disappeared completely. The fuel tank sensor is now working perfectly, and I have not experienced any similar issues in the past months. It was a relief that the problem did not require dropping the fuel tank or replacing the entire sending unit as originally suspected. A proper diagnosis by a qualified mechanic can save both time and money, as sometimes these fuel sensor faults have simple solutions rather than requiring major component replacements.

The mechanic visit turned out to be way better than expected. Took it to the shop yesterday and they diagnosed the fuel level sensor fault quickly. The car electronics were acting up due to a loose connector near the fuel tank sensor, not the major repair I was dreading. Total cost came to 85€ for diagnostic and fixing the connection. Much better than the hundreds I was worried about spending. The mechanic showed me how the corroded connection was causing the faulty sensor readings on the car dashboard. Car has been running perfectly since the fix, no more stalling at idle and the fuel gauge is showing correct readings. Really glad I got it checked out before it led to bigger problems. Sometimes these issues have simple fixes if you find the right shop that knows what they are doing. This turned out much better than my last shop experience where I got charged for unnecessary repairs. Just wanted to close the loop here in case anyone else runs into similar fuel sensor problems with their hybrid.