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

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

20-23

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

20-44

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.

- Install surge housing inner section, supply hose
and cover flange in fuel tank.

Note:
For clarity, the inner and outer surge housing sections are shown without
the tank. - Place inner section of surge housing into outer section of surge
housing (in tank) in such a way that notch 1 on inner section of surge
housing matches mark 2 on outer section of surge housing.
The inner section of the surge housing can be pressed downward
until it is clearly heard to engage.
- Put fuel pump wrench 3307 in place and turn surge housing inner
section with pump to the right approx. 15 to the stop. The notch -1-
will then be in front of the marking -3- (bayonet closure).
Pa
ge 40 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

20-52

Installing
Installation is performed in the reverse order of
the removal procedure, when installing, note the
following:

- Install the sender for fuel gauge in the guide on
the surge housing outer section and press down
until it engages.

- Wrap sender for fuel gauge wiring once around
return line (in tank).

Cover flange, installing Page 20
-45
.

- Connect Ground strap to Battery with ignition
switched OFF.

- After connecting Battery, input radio anti-theft
coding.

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

-
Operate all window lifters again for at least 1
Pa
ge 48 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