fuel pump AUDI A4 1996 B5 / 1.G Fuel Supply System Biturbo 2.8 User Guide

20-118

Fuel pump, removing and installing


Vehicles with 2.7 ltr. turbo engine
Observe all safety precautions Page 20-1 .
Observe rules of cleanliness Page 20
-4 .

Special tools needed:
Wrench 3217 for threaded cap nut

Wrench 3307 for fuel pump
Pa
ge 13 of 25 Fuel su
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20-119

Removing

- Obtain radio code for radio with anti-theft
coding.

- Switch off ignition and disconnect battery ground
(GND) cable.

- Briefly open fuel filler cap and then close it
again.

- Empty fuel tank if necessary using fuel
evacuator unit VAG1433 A.


Front wheel drive Page 20
-18
.


All wheel drive Page 20
-66
.

Note:

The fuel tank may not be filled more than
1/3.

- Remove luggage compartment liner.

- Remove cover for fuel pump flange.

WARNING!
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ge 14 of 25 Fuel su
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20-120


- Mark fuel return line -2- and fuel supply line -3- and disconnect from
flange.
- Unclip 4-pin connector -1- and disconnect connector.

- Remove threaded cap nut with wrench 3217.
- Remove fuel pump flange and seal from fuel tank opening.
- On inside of flange disconnect connector for fuel gauge sender.
- Disconnect fuel return line on inside of flange (press release tabs).
Pa
ge 16 of 25 Fuel su
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gine
)
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20-121


Installing
Installation is in reverse order of removal, but do the following:
Note:
Secure all hose connections with hose clamps identical to factory-installed
clamps.
Parts catalog. - Insert wrench 3307 through fuel tank opening and place on inner part
of fuel accumulator housing.
-
Turn wrench 3307 approx. 15 to the left to stop and remove fuel
pump with inner part of fuel accumulator housing. - Install inner fuel accumulator housing, fuel supply hose and fuel pump
flange in fuel tank.
Pa
ge 17 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo en
gine
)
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play?action=Goto&t
yp
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pair&id=AUDI.B5.GE04.20.4

20-122


Note:
The fuel accumulator housing is shown in the illustration without fuel tank. - Install outer fuel accumulator housing in fuel tank by aligning notch -1-
on inner accumulator housing with notch -2- at outer accumulator
housing.
The inner accumulator housing can be pushed down noticeably.
- Apply wrench 3307 and turn inner fuel accumulator housing with pump
approx. 15 to the right to stop. Notch -1- is then aligned with marking
-3- (bayonet-type connection).

Note:
Lubricate O-rings with fuel before installing. - When installing, turn flange to the right (direction of arrow).
- Connect fuel return line on the inside of flange.
Pa
ge 18 of 25 Fuel su
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ly system, servicin
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gine
)
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p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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pair&id=AUDI.B5.GE04.20.4

20-126

Test sequence

- Remove luggage compartment liner.

- Remove cover for fuel pump.

- Unclip 4-pin connector and disconnect.

If the fuel tank contains fuel, the measured value must be between the
specified values for full and empty. - Measure resistance at both terminals -2- and -3- at fuel pump flangeSender
Tank full
Tank empty
Sender for fuel gauge -G
40
280
Pa
ge 22 of 25 Fuel su
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ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-128

Sender for fuel gauge -G, removing and
installing


Vehicles with 2.7 ltr. turbo engine
Observe all safety precautions Page 20
-1 .
Observe rules of cleanliness Page 20
-4 .

Removing

- Fuel pump flange, removing Page 20
-118
.

- Carefully lift out fuel pump flange with fuel
supply line connected and set aside.

- On the inside of the fuel pump flange disconnect
connector for fuel gauge sender.

Note: - Remove sender by pressing tab -arrows-.
The fuel accumulator housing is shown in the illustration without the
fuel tank. The illustration shows the fuel gauge sender for vehicles with front
wheel drive.
Pa
ge 24 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-129

Installing
Installation is in reverse order of removal, but do
the following:

- Install sender for fuel gauge in guides of outer
fuel accumulator housing and press down until
locked in place.

Fuel pump flange, installing Page 20
-121
.
Observe note regarding disconnecting battery.
Pa
ge 25 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4