AUDI A4 1997 B5 / 1.G Quattro Fuel Syst

20-92

Removing

CAUTION!

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

Note:
The fuel tank must not be filled to more than
1/3 maximum. - Disconnect Battery Ground strap with ignition switched OFF.
- Open fuel tank cover briefly and close again.
- If necessary, drain fuel tank using fuel cart Page 20
-66
.
- Remove connector flange cover under luggage compartment trim.
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20-93

WARNING!

Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.

- Mark return line -2- and supply line -3- and disconnect from cover
flange.
- Unlatch and disconnect 4-pin harness connector -1-.

- Unscrew union nut using 3217 wrench .
- Remove cover flange and sealing ring from fuel tank opening.
- Disconnect fuel level display harness connector on inside of flange
cover.
- Disconnect return line on inside of cover flange (press unlatching
buttons).
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20-94


- Insert 3307 wrench through fuel tank opening and place over the inner
section of the surge housing.
-
Using 3307 wrench, turn inner section of surge housing approx. 15 to
the left up to the stop and withdraw fuel pump assembly complete with
the inner housing section.
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)
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20-95

Cover flange and surge housing inner
section, pre-assembling
If cover flange and supply unit were separated

- Pre-assemble parts Page 20
-78
.

Note:
Install a toothed washer beneath each nut.
Angle position, cover flange to inner section of surge housing: 10
- Press together clamps for supply line (between pump and cover flange)
with VAG1275 pliers.
- Attach wiring to fuel pump.
M4: 1.5 Nm M5: 2 Nm
- Attach wiring with fuel-resistant cable ties.
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gine
)
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20-96

Installing
Installation is performed in the reverse of
removal, when installing, note the following:

CAUTION!

Always refer to the latest parts catalog to
ensure that you use original equipment fuel
hose clamps.

- Install surge housing inner section, supply hose
and cover flange in the fuel tank.

Note:
For clarity, the surge housing outer and inner sections are shown in the
illustration without the fuel tank. - Place inner section of surge housing into outer section of surge
housing in tank such that notch -1- on inner section of surge housing
matches mark -2- on outer section of surge housing.
The inner section of the surge housing can be audibly pressed
downward.
- Attach 3307 pump wrench and turn surge housing inner section to the
right approx. 15 (up to the stop). Notch -1- will then be in front of mark -3- (bayonet closure)
Pa
ge 45 of 55 Fuel su
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)
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20-97


Note: - When installing, turn cover flange in direction of arrow to the right as
shown in the illustration.
- Connect the return line inside on the cover flange.
Always use new O-rings. Lubricate O-rings with fuel or coat with lubricant.Install new cover flange gasket (dry) in fuel tank opening.
- Wrap sender for fuel gauge wire once around the supply line (in fuel
tank) and install on cover flange.

Note:
-Arrow 3- only applies to vehicles with front-wheel drive. - Attach cover flange to fuel tank
Vehicles with all wheel drive: arrow 1 must be opposite arrow 2
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)
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20-98


Note:
Ensure that fuel hoses fit tightly.
Radio operating instructions - Tighten union nut with 3217 wrench.
60 Nm
- Connect wiring and harness connector.
- Connect Battery Ground strap with ignition switched OFF.
- After connecting Battery, input radio anti-theft code
- Run door windows up to stop using electric window lifters.
- Operate all window lifters again for at least 1 second in "closed"
position to activate automatic up/down.
- Set the clock.
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)
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20-99

Sender for fuel gauge -G, checking


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

Required special tools, testing equipment
and auxiliary equipment

Fluke 83 multimeter
VW 1594 Adaptor kit

- Remove connector flange cover under luggage
compartment trim.

- Unlatch and disconnect 4-pin harness connector -1-.
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)
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20-100


Note: - Measure resistance at terminals -2- and -3- on cover flange
Sensor
Tank full
Tank empty
Sender for fuel gauge -G
40
280
If fuel level falls between "Tank full" and "Tank empty", resistance
value between the two specified values must be displayed. If 0 or is displayed there is an open or closed circuit in tank
wiring. To check "Tank full" or "Tank empty" resistance values; remove
sender for fuel gauge -G Page 20
-101
and swing sensor float to top
or bottom stop.
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)
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pair&id=AUDI.B5.GE04.20.3

20-101

Sender for fuel gauge -G, removing and
installing


Vehicles with all 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 .

Removing

CAUTION!

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

Note:
Fuel tank must not be filled higher than
1/3 maximum. - Disconnect Battery Ground strap with ignition switched OFF.
- Open fuel tank cover briefly and close again.
- If necessary, drain fuel tank using fuel cart Page 20
-66
.
Fuel supply unit, removing Page 20
-91
.
Pa
ge 50 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