AUDI A4 1995 B5 / 1.G Fuel Supply System Front Wheel Drive 1.8T And 2.8 Owner's Manual

20-25

CAUTION!

After installation, check for continuity
between Ground clamp on filler neck and
chassis Ground.

Specification: approximately 0 .

- With ignition switched OFF, connect Battery
Ground strap.

- After connecting Battery, input Radio anti-theft
coding

Radio operating instructions
- Run door windows up to stop with window
switches.

- Operate all window lifters again for at least 1
second in "closed" position to activate the
automatic up/down.

- Set the clock.
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20-26

Tightening torques

Component
Nm
Clamp bands for fuel tank on body 25
Aerodynamic trim (on body) in front of rear
axle 10
Cover on spare wheel well 10
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20-27


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

Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Sealing ring
-Replace
Installing: insert (dry) into fuel tank opening
2 -
O-rings
- Always replace.
- Check installation position
3 -
Return line From fuel distributor
- Mark before removal
- Note direction of arrow on connecting
flange
4 -
Supply line To fuel distributor
- Mark before removal
- Note direction of arrow on connecting
flange
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20-28


5 -
Cover flange
Removing and installing Page 20
-40
Location: Note arrow Mark Page 20
-46
6 -
Harness connector
For fuel pump and sender for fuel gauge -G
7 -
Hose guide Installed position as shown.Must be kept in position while union nut is
being tightened.
8 -
Union nut 60 Nm
- Remove and install using 3217 wrench
9 -
Wiring to fuel pump
- Attach with fuel resistant cable ties (item
10 )
10 -
Supply line Fuel pump/surge housingLocation Page 20
-43
2 Nm
- Install toothed washer beneath
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20-29


Repair Manual, Fuel Injection & Ignition, Repair
Group 24 11 -
Nut M4
1.5 Nm
- Install toothed washer beneath
12 -
Nut M5
13 -
Fuel supply unit Removing and installing Page 20
-40
- Electrically check fuel pump Page 20
-
31

- Check the residual pressure14 -
Fuel strainer
Connected to fuel supply unitCan not be individually replaced
- Clean if dirty
15 -
Surge housing lower section Mounted in fuel tankCan not be removedDisconnecting: press unlatching buttons on
connector piece
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20-30


16 -
Sender for fuel gauge -G
Float is cube shapedChecking Page 20
-48
Removing and installing Page 20
-50
17 -
Return line
Installed inside cover flange
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20-31

Fuel pump, electrical checking


Vehicles with front 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
VW 1594 Adaptor kit
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20-32

Checking requirements

Battery Voltage 12 Volts minimum

Fuse 28 OK

Relay 6 in Fuse/Relay panel OKFuel filter OK Ignition switched OFF.
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20-33

Test sequence

- Open fuse box cover on left side of instrument
panel.

- Pull fuse 28 from fuse holder (left row, 5Th fuse
from top)

Note:
The fuel pump runs very quietly. Avoid ambient background noise as
much as possible during fuel pump checks.
If running noise not audible - Connect VAG1348/3A remote control on right side of fuse holder 28
using VAG1348/3-2 adaptor wire -arrow-.
- Connect test lead to Battery +.
- Press remote control switch.
Fuel pump running noise must be audible
- Remove connector flange cover under luggage compartment trim.

- Unlatch and disconnect 4-pin harness connector -1-.
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20-34


If specified value obtained but no running noise audible from pump
WARNING!
Fuel system is under pressure! Before opening, place clean cloths
around the connections to be opened. Carefully loosen the
connections to relieve pressure. - Switch Fluke 83 multimeter to 20 Volt range and connect to terminal 1
(green/yellow) and 4 (brown) of harness connector using jumper wires
from VW 1594 Adaptor kit.
- Press remote control switch continuously while reading Voltage.
Specified value: approx. Battery Voltage.
- Remove cover flange as follows:

- Mark supply line -2- and return line -3- and remove from cover flange.
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ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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