warning AUDI A4 1997 B5 / 1.G AFC Engine Fuel Supply System Components Workshop Manual

20-1


Fuel supply system
components, removing and
installing

WARNING!

Always be sure to comply with applicable
safety precautions when working on the fuel
system page 20
-3 .
Pay attention to rules of cleanliness page 20
-
2 .
Adjusting accelerator pedal cable page 20
-
15
.

Notes:

Hose connections are secured with clamp-type,
screw-type, spring-type clamps.
Always replace clamp-type with spring-type or
screw-type clamps.
Pa
ge 1 of 24 Fuel su
pp
ly system com
ponents, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.20.1

20-3

Safety precautions


WARNING!

When removing and installing the fuel pump
or fuel level sensor from a filled or partially
filled fuel tank:

BEFORE beginning repairs, the suction pipe
of an exhaust extraction system must be
located near the fuel tank opening so that
escaping fuel vapors can be immediately
carried away.
If no exhaust extraction system is available,
a radial fan (motor located outside airflow)
with volume of at least 15 m3/hr (9 cfm) may
be used.
Wear fuel-resistant gloves whenever working
with open parts of the fuel system.

Be sure the ignition is switched OFF, when:
Disconnecting fuel injection system wiring
Connecting or disconnecting test equipment
leads

BEFORE cranking the engine at starting RPM
Pa
ge 4 of 24 Fuel su
pp
ly system com
ponents, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.20.1

20-5

Flange and fuel level sensor, removing
and installing


Observe safety measures page 20
-3

Pay attention to rules of cleanliness page 20
-2 .

WARNING!

Fire hazard. DO NOT smoke or work near
heaters or have anything in the area that can
ignite fuel!

- Switch ignition on.

- Observe fuel gauge.

CAUTION!

The fuel tank should not be more than 2/3
full. Empty fuel tank, if necessary, using an
approved fuel cart.
Determine correct radio anti-theft coding
before disconnecting the battery.

Removing
Pa
ge 8 of 24 Fuel su
pp
ly system com
ponents, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.20.1

20-7

Fuel pump, removing and installing


Observe safety measures page 20
-3

Pay attention to rules of cleanliness page 20
-2 .
Removing and installing sealing flange and fuel
level sensor page 20
-5

WARNING!

Fire hazard. DO NOT smoke or work near
heaters or have anything in the area that can
ignite fuel!

Removing

Installing
Installation is in reverse order of removal.
Note: - Insert fuel pump wrench 3307 through fuel tank opening and position at
inner part of fuel reservoir housing.
-
Turn inner part of reservoir housing about 15 to left as far as stop and
remove fuel pump along with inner part of reservoir housing.
Moisten the flange seal with fuel before installing.
Pa
ge 11 of 24 Fuel su
pp
ly system com
ponents, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.20.1

20-10

Fuel pump, testing


WARNING!

Fire hazard! DO NOT smoke or work near
heaters or have anything in area that can
ignite fuel!

Checking power supply

Battery fully charged
Fuse 28 OK
Test voltage supply to fuse 28 Repair
Manual, 2.8 Liter V-6 OBD II Fuel Injection
and Ignition, Repair Group 24

Fuel supply OK

- Switch ignition on.
Fuel pump must be heard to run briefly.
(Second person will be required for this if
surrounding noise level is too high).
If fuel pump does NOT run:

Pa
ge 15 of 24 Fuel su
pp
ly system com
ponents, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.20.1