fuel AUDI A4 2000 B5 / 1.G Quattro Fuel Syst

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

20-73


Note:
Ensure that the bleed line stays clipped to the fuel tank during fuel tank
removal. - Disconnect clamp bands and carrier plate -arrows-.
- Lower fuel tank.
Pa
ge 22 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

20-74

Installing
Installation is performed in the reverse order of
removal, during installation note the following:

CAUTION!

Always refer to the latest parts catalog to
ensure that you use original equipment fuel
hose clamps.

Note:

Secure all hose connections using spring
clamps:
VAG1921 Hose clamp pliers are recommended
for installing spring clamps.
Always replace sealing rings and gaskets
during installation work.

- Ensure that Ground connection -arrow- connects to metal ring on filler
neck.
Check Ground wire routing.
Pa
ge 23 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

20-76


CAUTION!
After installation, check for continuity between Ground clamp on
filler neck and chassis Ground.
Radio operating instructions - Connect lines according to markings:
1 - Supply line
2 - Bleed line to EVAP canister
3 - Return line
- Re-connect fuel pump and sender for fuel gauge harness connectors.
Specification: approximately 0 .
- Connect Ground strap to Battery with ignition OFF.
- After connecting Battery, input radio anti-theft code- Run door windows up to the stop using window switches.
- Operate all window switches again for at least 1 second in "closed"
position to activate automatic up/down.
- Re-set the clock.
Pa
ge 25 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

20-77

Tightening torques

Component
Nm
Clamp bands and/or carrier plate (for fuel
tank) on chassis 25
Nm
Clamp bands on fuel tank 2 Nm
Carrier plate on fuel tank 2 Nm
Cover on spare wheel well 10
Nm
Pa
ge 26 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

20-79


4 -
O-rings
- Always replace.
- Check installation position
5 -
Return line
From fuel distributor
- Mark before removal
- Note direction of arrow on flange
6 -
Supply line To fuel distributor
- Mark before removing
- Note direction of arrow on flange
7 -
Cover flange Removing and installing Page 20
-91
Location: Note arrow marking Page 20
-
97

8 -
Harness connector
For fuel Pump and sender for fuel gauge -
G
Pa
ge 28 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

20-80


9 -
Union nut
60 Nm
10 -
Wiring To fuel pump
- Attach with fuel resistant cable ties (item
11 )
11 -
Supply line Fuel pump/surge housingLocation Page 20
-95
12 -
Nut M4
1.5 Nm
- Install toothed washer beneath.
13 -
Nut M5 2 Nm
- Install toothed washer beneath.
Pa
ge 29 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

20-81


Repair Manual, Fuel Injection & Ignition, Repair
Group 24 14 -
Fuel supply unit
Removing and installing Page 20
-91
- Fuel pump electrical checks Page 20
-
82

- Residual pressure, checking:15 -
Fuel strainer
Connected to fuel supply unitCan not be replaced individually
- Clean if dirty
16 -
Surge housing lower section Installed in fuel tankCan not be removed
Pa
ge 30 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