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

20-6


Fuel supply system, servicing
(vehicles with front wheel drive
and 1.8 ltr. turbo or 2.8 ltr.
engine) Note:
CAUTION!
Always refer to the latest parts catalog to
ensure that you use original equipment fuel
hose clamps.
VAG1921 spring clamp pliers are recommended
for installation
Always replace seals, O-rings and gaskets
during installation work.
Pa
ge 1 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
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pair&id=AUDI.B5.GE04.20.2

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

20-8


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

20-9


14 -
Bleed line
To EVAP canister
15 -
Fuel tank Removing and installing Page 20
-19
16 -
25 Nm
- Note tightening sequence Page 20
-23
17 -
Bracket
For clamp bands
18 -
Clamp bands Removing and installing Page 20
-19
- Note different lengths
- Note installation direction
Pa
ge 4 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
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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

20-12


4 -
O-ring
-Replace
5 -
O-rings
-Replace
6 -
Bleed valve
Removing, installing, checking Fig. 1
,
Page 20
-13

Pa
ge 7 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

20-13


Fig. 1 Bleed valve removing, installing, checking
- To remove, unclip valve from side of filler neck.

Lever in rest position: Valve closed
Lever pressed in direction of arrow: Valve open
Pa
ge 8 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

20-14


Fuel filler neck, component overview
(vehicles with ORVR)

Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Bleed line
To top of filler neck on fuel tank
2 -
Expansion tank Clipped to fuel-filler neck
3 -
Tank ventilation valve Clipped to fuel-filler neckVentilates fuel tank for pressure
compensation
Pa
ge 9 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