AUDI A4 1997 B5 / 1.G Quattro Fuel Syst

20-53


Fuel supply system, servicing
(vehicles with all wheel drive
and 1.8 ltr. turbo or 2.8 ltr.
engine) Fuel tank assembly, component overview

Note:
Repair Manual, Fuel Injection & Ignition, Repair
Group 24
Checking fuel pump relay and triggering: Secure all hose connections using spring
clamps.
VAG1921 pliers are recommended for installing
spring clamps
Always replace sealing rings and gaskets during
installation work.
Always refer to the Parts Catalog for availability
of individual items in an assembly.
Pa
ge 1 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-54


1 -
Plastic nut
2 Nm
- Lightly twist on to fasten fuel tank clamp
bands
- Tighten nut after tightening clamp bands
2 -
Clamp bands Removing and installing Page 20
-69
- Note different lengths
- Note installation orientation
3 -
Banjo bolt M14
30 Nm
4 -
1.2 Nm
5 -
Fuel filter Location: Arrow points in direction of flow.
6 -
Supply line To fuel supply on fuel distributor
7 -
Sealing ring
-Replace
8 -
Banjo bolt M12 20 Nm
Pa
ge 2 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-55


9 -
Protector plate
For fuel filler neckWith Ground connection
- Before installing a mounting screw (item
10 ) ensure that screw eye of Ground
connection fits tightly
10 -
25 Nm
11 -
Ground connection Location Fig. 1
, Page 20
-58
- Ensure tight fit of metal ring on fuel filler
neck
- Check chamfer on protective plate (Item
9 ).
- After installation, check continuity
between metal ring on fuel filler neck and
chassis Ground: must be approx. 0 12 -
Cover
13 -
Gasket
- Replace if damaged.
Pa
ge 3 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-56


14 -
Locking ring
15 -
Rubber cap
16 -
Overflow hose
17 -
Bleed line
Between EVAP canister and EVAP
canister purge regulator valve N80
18 -
Bleed line Between the bleed valve on fuel filler neck
and EVAP canister
19 -
Fuel tank Removing and installing Page 20
-69
20 -
Heat shield
For fuel tankFastened on rear edge of fuel tank with
adhesive tape
Pa
ge 4 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-57


21 -
Plastic nut
2 Nm
22 -
Carrier plate
23 -
Heat shield For fuel filler neck
24 -
Mounting clamp
- Ensure tight fit
25 -
Plastic nut 2 Nm
26 -
25 Nm
Pa
ge 5 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-58


Fig. 1 Ground connection, installed position
- Route the Ground connection -Arrow-, as shown in illustration.
- Ensure Ground connector fits tightly on filler neck Ground clamp.

CAUTION!
After installation, check for continuity between Ground clamp on
filler neck and chassis Ground. Fig. 2 Ground connection, installed position, cont.
- Before threading in screw -1-, ensure tight fit of screw eye -2- on fuel
filler neck protection plate Ground -3-.
Specification: approximately 0 .
Pa
ge 6 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-59


Fuel filler neck, component overview
(vehicles without ORVR)

Vehicles with all wheel drive and 1.8 ltr. turbo or
2.8 ltr. engine
1 -
Expansion tank
- Attach wires to expansion tank using
adhesive tape
2 -
Bleed lines
To connector line at top of fuel tank
3 -
Bleed line To EVAP canister
4 -
Gravity valve Removing: unclip upward out of the filler
neck
- Check valve for flow:
Valve vertical: Flow

Valve tipped 45 : No Flow
5 -
O-ring
-Replace
Pa
ge 7 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-60


6 -
Ground connection
Location Fig. 1
, Page 20
-58
- Ensure tight fit of metal ring on fuel filler
neck
- Check chamfer on protective plate (item
7 ).
- After installing, check continuity between
metal ring on fuel filler neck and chassis
Ground using multimeter, specified
value: approx. 0
7 -
Protector plate
For fuel filler neckWith Ground connection
- Ensure Ground screw is tight before
threading in mounting screw (item 10
Page 20
-55
)
8 -
O-rings
-Replace
9 -
Bleed valve
Removing, installing, checking Fig. 1
,
Page 20
-61

Pa
ge 8 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-61


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 9 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3

20-62


Fuel filler neck, component overview
(vehicles with ORVR)

Vehicles with all wheel drive and 1.8 ltr. turbo or
2.8 ltr. engine
1 -
Expansion tank
- Secure wires to expansion tank using
adhesive tape
2 -
Bleed lines
To connector line at top of fuel tank
3 -
Tank protection valve Clipped to fuel filler neckVentilates fuel tank for pressure
compensation
4 -
Gravity valve To remove valve, unclip upward out of the
filler neck
- Check valve for flow:
Valve vertical: Flow

Valve tilted 45 : No Flow
5 -
O-ring
-Replace
Pa
ge 10 of 55 Fuel su
pp
ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3