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

20-24


CAUTION!
Ensure that the Ground connection is unfastened and the connector
is securely fitted into the fuel filler neck Fig. 1
, Page 20
-10
. - Attach wiring terminal -1- with screw -2- for fuel filler neck.

- Connect lines according to marks:
1 - Supply line
2 - Return line
- Connect fuel pump and sender for fuel gauge -G harness connectors.
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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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20-31

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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20-33

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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20-35


- Unscrew union nut using 3217 wrench.
- Remove cover flange and sealing ring from fuel tank opening.

If wiring OK; fuel pump is faulty - Check wiring for continuity between flange and fuel pump.
- Replace fuel supply unit Page 20
-40
- Re-install cover flange Page 20
-44
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20-36

Fuel pump delivery volume, 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
Calibrated measuring container

Checking requirements
Battery Voltage: 12 Volts minimum
Fuel filter OK
Ignition switched OFF.
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20-39

All vehicles

- Operate remote control for 15 seconds.

Press remote button continuously

*) Minimum supply quantity cm
3/15 s
**)
Voltage on fuel pump with engine off and pump running (approx. 2
Volts less than Battery Voltage). - Compare fuel quantity pumped to specified value.
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20-40

Fuel supply unit, 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

3217 Union nut wrench
3307 fuel pump wrench
VAG1275 Hose clamp pliers

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.
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