VW Passat Hybrid Stalling Issue Fixed with Sensor Swap

As someone with moderate experience working on VWs, I dealt with nearly identical symptoms on my VW Golf GTE Hybrid 2014. The car dashboard was showing similar warning lights and sensor fault codes. Initially, I suspected a faulty sensor in the fuel system too, but when I took it to the workshop, they diagnosed a blown fuse that was affecting multiple car electronics systems, including the fuel level sensor. The intermittent stalling was happening because the ECU was getting incorrect readings. The fix was surprisingly simple and cost 52€, which covered diagnostic time and fuse replacement. Since the repair, the check engine light has stayed off and the stalling issue completely resolved. Before suggesting this might be your exact issue, could you share: Which specific error codes are stored, Whether the stalling happens only when the car is warm or cold, If you notice any other warning lights on the dashboard, Whether the hybrid system shows any separate warnings This information would help determine if your case matches what I experienced or if you might be dealing with a different underlying problem.

Thanks for your input. Just had my latest service 2 weeks ago at 145000km and everything checked out fine until these issues started. The error codes are P0461 and P0462 which seem to confirm the fuel sensor malfunction theory. The stalling only occurs when the engine is warm, typically after 15-20 minutes of driving. No additional warning lights beyond the check engine light, and the hybrid system appears to function normally. The fuel gauge readings have become erratic lately, jumping between levels, which makes me think the faulty sensor in the fuel tank might be the root cause rather than a fuse issue. Would you recommend getting a complete fuel sensor replacement or is there a way to test the sensor first?

Having gone through this exact scenario with my Golf GTE, I can now confirm your issue sounds more severe than my initial fuse problem. The error codes P0461 and P0462 definitely point toward a fuel level sensor malfunction, which is quite different from what I encountered. The erratic fuel gauge behavior combined with the warm engine stalling is a classic sign of a failing fuel tank sensor assembly. In my case, after the fuse replacement failed to solve similar symptoms long-term, the workshop found the actual fuel level sensor had corroded connections. The complete fuel sensor replacement ended up costing 320€, including labor. The mechanic tested the sensor beforehand using diagnostic equipment, but the testing cost was included in the repair price since they had to drop the fuel tank anyway. This repair completely resolved both the stalling and erratic gauge readings. Looking back, I should have addressed the jumpy fuel gauge readings earlier, as they were the first warning sign of the failing sensor. Would recommend asking your workshop to perform voltage testing on the fuel level sensor circuit before replacement, though based on your symptoms and those specific error codes, you likely need the complete sensor assembly replaced.

Based on your detailed explanation and comparing it with my car's symptoms, I think you're right about going straight for the sensor testing and likely replacement. The matching error codes and especially the erratic fuel gauge behavior really point to a faulty sensor in the fuel system rather than a simple fuse issue. I just called my regular workshop and booked an appointment for next week. They quoted roughly 350€ for a complete fuel sensor replacement if needed, which sounds in line with what you paid. They mentioned they will perform the diagnostic testing first, but agreed the symptoms strongly suggest a sensor fault. Going to have them check the entire fuel system while they are at it, since the tank needs to be dropped anyway. Better to handle everything at once rather than risk having car electronics issues pop up again shortly after. Thanks for sharing your experience. It helped confirm my initial suspicion about the sensor and gave me a good idea of the repair costs to expect. Will update once the work is done in case anyone else runs into similar issues with their hybrid.