engine AUDI A4 1995 B5 / 1.G Fuel Supply System Front Wheel Drive 1.8T And 2.8 Workshop Manual

20-6


Fuel supply system, servicing
(vehicles with front wheel drive
and 1.8 ltr. turbo or 2.8 ltr.
engine) Note:
CAUTION!
Always refer to the latest parts catalog to
ensure that you use original equipment fuel
hose clamps.
VAG1921 spring clamp pliers are recommended
for installation
Always replace seals, O-rings and gaskets
during installation work.
Pa
ge 1 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
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20-7


Fuel tank assembly, component overview

Note:
Always refer to the Parts Catalog for availability of
individual items in an assembly.
Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Return line
From engine
- Mark before removing
- Note direction of arrow on connecting
flange
2 -
20 Nm
3 -
Fuel filter Location: Arrow points in flow direction.
4 -
Holding clamp For fuel filter
5 -
Supply line To the fuel filter
- Mark before removal
- Note direction of arrow on connecting
flange
Pa
ge 2 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2

20-11


Fuel filler neck, component overview
(vehicles without ORVR)

Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Ground connection
Location Fig. 1
, Page 20
-10
- Ensure tight fit of connector on filler neck
ring
- Connect wiring terminal with mounting
screw for plastic fuel filler neck (item 6
Page 20
-8 )
- After installing, check continuity between
metal ring on fuel filler neck and chassis
Ground. Specified: approx. 0
2 -
Bleed line
To EVAP canister
3 -
Gravity valve To remove valve, unclip upward out of the
filler neck
- Check valve for flow:
Valve vertical: open,

Valve tipped 45 : closed
Pa
ge 6 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2

20-14


Fuel filler neck, component overview
(vehicles with ORVR)

Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Bleed line
To top of filler neck on fuel tank
2 -
Expansion tank Clipped to fuel-filler neck
3 -
Tank ventilation valve Clipped to fuel-filler neckVentilates fuel tank for pressure
compensation
Pa
ge 9 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2

20-18

Fuel tank, draining


Vehicles with front 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 .

Auxiliary equipment required

FM 3000 fuel cart (or equivalent)

CAUTION!

Obtain the radio Anti-theft code from the
customer before disconnecting the Battery
Ground strap.

- Disconnect Battery Ground strap with ignition switched OFF.
- Remove filler cap from fuel filler neck.
- Empty fuel tank as completely as possible through the filler neck.
Pa
ge 13 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2

20-19

Fuel tank assembly, removing and
installing


Vehicles with front wheel drive and 1.8 ltr.
turbo or 2.8 ltr. engine
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 / transmission jack

Removing

CAUTION!

Obtain the radio Anti-theft code from the
customer before disconnecting the Battery
Ground strap.

- Disconnect Battery Ground strap with ignition switched OFF.
- Open fuel tank cover briefly and close again.
Pa
ge 14 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2

20-22

- Remove EVAP canister cover on bottom of
spare tire well Page 20
-130
.

Note:
Bleed line -2- to the EVAP canister purge regulator valve remains
connected. - Loosen hose connection -1- on bleed line to fuel filler neck.
- Unclip line out from bracket -arrow-.
- Place VAG1383A engine / transmission jack under fuel tank for
support.
- Mark installation position of clamp bands.

Note:
Arrow points in driving direction. - Remove clamp bands -1- to -4-.
- Lower fuel tank.
Pa
ge 17 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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pair&id=AUDI.B5.GE04.20.2

20-23

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

CAUTION!

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

Note:

Replace all adhesive tapes removed during
disassembly in the original location during
installation.
Use VAG1921 hose clamp pliers to install
spring clamps,
Always replace sealing rings and gaskets
during installation work.

- Position fuel tank using clamp strips with
VAG1383 A engine / transmission jack on
vehicle floor pan.

- Push fuel tank all the way to the left.
Pa
ge 18 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2

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
Pa
ge 23 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2

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
Pa
ge 27 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.2