engine AUDI A4 1997 B5 / 1.G Quattro Fuel Syst

20-53


Fuel supply system, servicing
(vehicles with all wheel drive
and 1.8 ltr. turbo or 2.8 ltr.
engine) Fuel tank assembly, component overview

Note:
Repair Manual, Fuel Injection & Ignition, Repair
Group 24
Checking fuel pump relay and triggering: Secure all hose connections using spring
clamps.
VAG1921 pliers are recommended for installing
spring clamps
Always replace sealing rings and gaskets during
installation work.
Always refer to the Parts Catalog for availability
of individual items in an assembly.
Pa
ge 1 of 55 Fuel su
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ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-59


Fuel filler neck, component overview
(vehicles without ORVR)

Vehicles with all wheel drive and 1.8 ltr. turbo or
2.8 ltr. engine
1 -
Expansion tank
- Attach wires to expansion tank using
adhesive tape
2 -
Bleed lines
To connector line at top of fuel tank
3 -
Bleed line To EVAP canister
4 -
Gravity valve Removing: unclip upward out of the filler
neck
- Check valve for flow:
Valve vertical: Flow

Valve tipped 45 : No Flow
5 -
O-ring
-Replace
Pa
ge 7 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-62


Fuel filler neck, component overview
(vehicles with ORVR)

Vehicles with all wheel drive and 1.8 ltr. turbo or
2.8 ltr. engine
1 -
Expansion tank
- Secure wires to expansion tank using
adhesive tape
2 -
Bleed lines
To connector line at top of fuel tank
3 -
Tank protection valve Clipped to fuel filler neckVentilates fuel tank for pressure
compensation
4 -
Gravity valve To remove valve, unclip upward out of the
filler neck
- Check valve for flow:
Valve vertical: Flow

Valve tilted 45 : No Flow
5 -
O-ring
-Replace
Pa
ge 10 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-66

Fuel tank, draining


Vehicles with all wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine

WARNING!

Fire hazard! Do NOT have anything in the
area that can ignite gasoline!
Observe Safety measures Page 20
-1 .
Observe Rules of cleanliness Page 20
-4 .

Required equipment

FM 3000 fuel storage cart (or equivalent)
Pa
ge 14 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-69

Fuel tank assembly, removing and
installing


Vehicles with all wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine

WARNING!

Fire hazard! Do NOT have anything in the
area that can ignite gasoline!
Observe Safety measures Page 20
-1 .
Observe Rules of cleanliness Page 20
-4 .

Required special tools, testing equipment
and auxiliary equipment

VAG1359/2 Universal holder
VAG1383 A Engine and transmission jack
Pa
ge 17 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-72

WARNING!

Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.

- From bottom of vehicle, mark supply line -1-, return line -3- and bleed
line to EVAP canister and disconnect -2-.
- Remove the EVAP canister cover near bottom of spare wheel well
Page 20
-130
.

- Loosen hose connections -1- and -2- on bleed lines.
- Unclip line from bracket -arrow-.
- Place VAG1383A engine and transmission jack under the fuel tank for
support.
- Mark installed position of the clamp bands.
Pa
ge 21 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-75

- Loosely fasten clamp bands and carrier plate to
fuel tank.

- Position fuel tank on floor pan complete with
clamp bands and carrier plate using VAG1383 A
engine transmission jack.

CAUTION!
Ensure that Ground connection is surrounded with a protective
shield and connector on fuel filler neck is securely attached.
Installed position Fig. 1
, Page 20
-58
. - Before threading in mounting screw -1- ensure tight fit (chamfer) of
screw eye -2- on protective plate Ground connection -3- for fuel filler
neck.

- Screw the clamp bands and carrier plate tight -arrows-.
- Tighten plastic nuts on clamp bands and carrier plate.
Pa
ge 24 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-78


Fuel supply unit and sender for fuel gauge
-G, component overview

Vehicles with all wheel drive and 1.8 ltr. turbo or
2.8 ltr. engine
1 -
Sender for fuel gauge -G
Float is cube-shaped
- Check resistance values: Page 20
-99
Removing and installing: Page 20
-101
2 -
Return line
With fuel pumpOn inside of cover flangeRemoving and installing Page 20
-104
Disconnecting: press unlatch buttons on
connector piece
3 -
Sealing ring
-ReplaceInstalling: insert dry into fuel tank opening
Pa
ge 27 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-82

Fuel pump, electrical checking


Vehicles with all wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine

Required special tools, testing equipment
and auxiliary equipment

VAG1348/3A Remote control using
VAG1348/3-2 adaptor cable
Fluke 83 multimeter (or equivalent)
VW 1594A adaptor kit
Pa
ge 31 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-87

Fuel pump delivery volume, checking


Vehicles with all wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine

Required special tools, testing equipment
and auxiliary equipment

VAG1348/3A Remote control with VAG1348/3-
2 adaptor cable
Calibrated measuring container

Test requirements
Battery Voltage: 12 Volts minimum
Fuel filter OK
Ignition switched OFF.
Pa
ge 36 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3