fuel AUDI A4 1997 B5 / 1.G Fuel Supply System Front Wheel Drive 1.8T And 2.8 User Guide

20-16


6 -
O-ring
-Replace
7 -
Sealing ring
Installation position: Sealing lip points to
the fuel filler neck
8 -
O-rings Different sizes
-Replace
9 -
Bleed valve Removing, installing, checking Fig. 1
,
Page 20
-17

10 -
Bleed line
To EVAP canister
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20-17


Requirement
Tab -2- pressed in direction of arrow:
Tab -2- in OFF position: Fig. 1 Bleed valve, removing, installing, checking
Fuel tank removed
- To remove, unclip valve from side of filler neck.
- Plug port -3- by hand.
- Blow into port -1-Must be flow Must NOT be flow.
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20-18

Fuel tank, draining


Vehicles with front wheel drive and 1.8 ltr.
turbo or 2.8 ltr. engine

WARNING!

Fire hazard! Do NOT have anything in the
area that can ignite gasoline!
Observe Safety measures Page 20
-1 .
Observe Rules of cleanliness Page 20
-4 .

Auxiliary equipment required

FM 3000 fuel cart (or equivalent)

CAUTION!

Obtain the radio Anti-theft code from the
customer before disconnecting the Battery
Ground strap.

- Disconnect Battery Ground strap with ignition switched OFF.
- Remove filler cap from fuel filler neck.
- Empty fuel tank as completely as possible through the filler neck.
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20-19

Fuel tank assembly, 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

VAG1359/2 Universal holder
VAG1383 A Engine / transmission jack

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.
- Open fuel tank cover briefly and close again.
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20-20

- If necessary, drain fuel tank using fuel cart
Page 20
-18
.

Note:
For handling reasons, fuel tank must be empty
before removing.

- Remove connector flange cover under luggage
compartment trim.

Note:
Return line -2- and supply line -3- stay connected. - Unlatch and disconnect 4-pin harness connector -1-.
- Clean area around fuel filler neck.
- With filler cap removed, pry out clamping ring on rubber seal (around
filler neck).
- Push rubber seal toward inside.
- Remove right rear wheel.
- Remove right rear wheel house liner.

- Remove screw -2- for fuel filler neck under wheel house liner.
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20-21


WARNING!
Fuel system is under pressure! Before opening, place clean cloths
around the connections to be opened. Carefully loosen the
connections to relieve pressure. - If present, remove the aerodynamic trim panel from the rear axle -
arrows-

- Mark and remove the supply line -1- and return line -2- .
On bottom of vehicle
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20-22

- Remove EVAP canister cover on bottom of
spare tire well Page 20
-130
.

Note:
Bleed line -2- to the EVAP canister purge regulator valve remains
connected. - Loosen hose connection -1- on bleed line to fuel filler neck.
- Unclip line out from bracket -arrow-.
- Place VAG1383A engine / transmission jack under fuel tank for
support.
- Mark installation position of clamp bands.

Note:
Arrow points in driving direction. - Remove clamp bands -1- to -4-.
- Lower fuel tank.
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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.
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- First tighten screws -1- and -2-, then screws -3- and -4-.
25 Nm
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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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