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

20-8


6 -
Mounting screw
25 NmTo connect fuel-filler neck and Ground
(item 13 Page 20
-8 )
7 -
Washer
8 -
Overflow hose
9 -
Rubber cap
10 -
Locking ring
11 -
Sealing ring
- Replace if damaged.
12 -
Cover
13 -
Ground connection
Location Fig. 1
, Page 20
-10
- Connect wiring terminal with mounting
screw (item 6 ) Page 20
-8 .
- After installing, check continuity between
metal ring on fuel filler neck and bare
chassis Ground point. spec: approx. 0
Pa
ge 3 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

20-10


Fig. 1 Ground connection installation position
- Route Ground connection -arrow-, as shown in illustration.
- Ensure tight fit of electrical Ground connection to fuel filler neck Ground
clamp.

CAUTION!
After installation, check for continuity between Ground clamp on
filler neck and chassis Ground. - Attach wiring terminal -1- with screw -2- for fuel filler neck.
Specification: approximately 0 .
Pa
ge 5 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

20-15


4 -
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
ring on fuel filler neck and chassis
Ground, spec: approx. 0
5 -
Gravity valve
To remove valve, unclip upward out of filler
neck
- Check valve for flow:
Valve vertical: Flow

Valve tipped 45 : No Flow
Pa
ge 10 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

20-24


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.
Pa
ge 20 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

20-28


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
Pa
ge 24 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

20-35


- 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
Pa
ge 31 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

20-43

Cover flange and surge housing inner
section, pre-assembling
If cover flange and supply unit were separated

- Pre-assemble parts Page 20
-27
.

Note:
Install a toothed washer beneath each of the nuts.
Angle position cover flange to inner section of surge housing 10
- Press together clamps for supply line (between pump and cover flange)
using VAG1275 pliers.
- Attach wiring to fuel pump
M4: 1.5 Nm M5: 2 Nm
- Attach wiring using fuel-resistant cable ties.
Pa
ge 39 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

20-45


Note: - When installing, turn the cover flange in direction of arrow as shown in
illustration.
- Connect the return line inside on the cover flange.
Always use new O-rings. Lubricate O-rings with fuel or coat with a lubricant.Place the new gasket (dry) for the cover flange into the opening of the
fuel tank.
- Wrap sender for fuel gauge -G wiring once around the supply line (in
fuel tank) and install on cover flange.
Pa
ge 41 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

20-46


Note:
-Arrow 1- applies to vehicles with All-Wheel Drive (Not applicable). - Connect cover flange to fuel tank
Installation for vehicles with Front-Wheel Drive: -arrow 2- must be
opposite -arrow 3-.

Note:
Ensure that hose guide (item 7 Page 20
-28
) is kept in position while
tightening the union nut. - Tighten union nut with 3217 wrench.
60 Nm
- Connect wiring and harness connector.
Pa
ge 42 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