Audi A6 (AEL), error 542 needle lift sensor (G80)

[mrfree]

Hi all,
my A6 2500cc TDI 1995 (AEL engine) is actually undriveable!!! The engine makes "jump" when I drive and I'm afraid to accelerate because this amplify the effects

Using vag-com I found this error in the ECU log:

1 Fault found:
00542 - Needle lift Sensor (G80)
27-10 - Implausible Signal - Intermittent

I read AAT/AEL engine repair manual and I measured G80's ohmic resistance but I found it in range.

How can I try to solve this problem?

Thanks in advance

Edit: I forgot to say that I've changed fuel filter yesterday without any kind of change

[vw.audi-tech]

Is it a hard set code and always acts the same or will it ever drive normally? When you checked the resistance of the NLS was it at the bottom of the range? Since I have never worked on the V6 TDi I'm not sure if it has one or two sensors. Do you have diagnostic flowchart available to follow? I can look it up on AESIS and E-mail to you if you need.

Good Luck, Kevin

[mrfree]

Originally Posted by vw.audi-tech

Is it a hard set code and always acts the same or will it ever drive normally?

The problem seems to be pseudo-randomic
Sometime the engine makes a little-jump, sometime it makes lot of jumps and the car becomes undriveable.
I can't voluntarily reproduce the problem

Originally Posted by vw.audi-tech

When you checked the resistance of the NLS was it at the bottom of the range?

I've checked it some months ago, but if I remember well it should be about 98-100 ohm

Originally Posted by vw.audi-tech

Since I have never worked on the V6 TDi I'm not sure if it has one or two sensors.

The AEL engine has 5 cyl and one sensor (G80)

Originally Posted by vw.audi-tech

Do you have diagnostic flowchart available to follow? I can look it up on AESIS and E-mail to you if you need.

I haven't any diagnostic flowchart,
Can you send me it at mrfree_at_infinito_dot_it?

Thanks in advance.

[vw.audi-tech]

Sorry i havent been around lately. i will get to you as soon as i can
Kevin

[mrfree]

Ok, Thanks Kevin.

[mrfree]

Now I've installed a little switch in the car that I can use to manually disconnect G80 when the jumps are too frequent, so the engine runs with an emergency program (great power loss) but I can go home in a safe way.

Kevin, have you find something for me