fuel pump 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.
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11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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20-68

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-, supply line -3- and remove 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.
- Pump remaining fuel through the flange opening.
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11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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20-76


CAUTION!
After installation, check for continuity between Ground clamp on
filler neck and chassis Ground.
Radio operating instructions - Connect lines according to markings:
1 - Supply line
2 - Bleed line to EVAP canister
3 - Return line
- Re-connect fuel pump and sender for fuel gauge harness connectors.
Specification: approximately 0 .
- Connect Ground strap to Battery with ignition OFF.
- After connecting Battery, input radio anti-theft code- Run door windows up to the stop using window switches.
- Operate all window switches again for at least 1 second in "closed"
position to activate automatic up/down.
- Re-set the clock.
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11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE04.20.3

20-78


Fuel supply unit and sender for fuel gauge
-G, component overview

Vehicles with all wheel drive and 1.8 ltr. turbo or
2.8 ltr. engine
1 -
Sender for fuel gauge -G
Float is cube-shaped
- Check resistance values: Page 20
-99
Removing and installing: Page 20
-101
2 -
Return line
With fuel pumpOn inside of cover flangeRemoving and installing Page 20
-104
Disconnecting: press unlatch buttons on
connector piece
3 -
Sealing ring
-ReplaceInstalling: insert dry into fuel tank opening
Pa
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11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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20-79


4 -
O-rings
- Always replace.
- Check installation position
5 -
Return line
From fuel distributor
- Mark before removal
- Note direction of arrow on flange
6 -
Supply line To fuel distributor
- Mark before removing
- Note direction of arrow on flange
7 -
Cover flange Removing and installing Page 20
-91
Location: Note arrow marking Page 20
-
97

8 -
Harness connector
For fuel Pump and sender for fuel gauge -
G
Pa
ge 28 of 55 Fuel su
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ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
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)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE04.20.3

20-80


9 -
Union nut
60 Nm
10 -
Wiring To fuel pump
- Attach with fuel resistant cable ties (item
11 )
11 -
Supply line Fuel pump/surge housingLocation Page 20
-95
12 -
Nut M4
1.5 Nm
- Install toothed washer beneath.
13 -
Nut M5 2 Nm
- Install toothed washer beneath.
Pa
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g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
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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

20-81


Repair Manual, Fuel Injection & Ignition, Repair
Group 24 14 -
Fuel supply unit
Removing and installing Page 20
-91
- Fuel pump electrical checks Page 20
-
82

- Residual pressure, checking:15 -
Fuel strainer
Connected to fuel supply unitCan not be replaced individually
- Clean if dirty
16 -
Surge housing lower section Installed in fuel tankCan not be removed
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11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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pair&id=AUDI.B5.GE04.20.3

20-82

Fuel pump, electrical checking


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

Required special tools, testing equipment
and auxiliary equipment

VAG1348/3A Remote control using
VAG1348/3-2 adaptor cable
Fluke 83 multimeter (or equivalent)
VW 1594A adaptor kit
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11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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20-84

Test sequence

- Open fuse box cover on left side of instrument
panel.

- Remove fuse 28 from fuse panel

Left row, 5Th fuse from top

Note:
The fuel pump runs very quietly. Avoid ambient background noise as
much as possible during fuel pump checks.
If pump running noise is not audible - Connect remote control VAG1348/3A on right side of fuse socket 28
using VAG1348/3-2 adaptor wire -arrow-.
- Connect clamp to Battery +.
- Press remote control switch.
Fuel pump when running must be audible.
- Remove connector flange cover under luggage compartment trim.

- Unlatch and disconnect 4-pin harness connector -1-.
Pa
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ly system, servicin
g (vehicles with all wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
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)
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE04.20.3

20-85


If specified value obtained but no audible sound from pump
WARNING!
Fuel system is under pressure! Before opening, place clean cloths
around the connections to be opened. Carefully loosen the
connections to relieve pressure. - Switch Fluke 83 multimeter to 20 Volt range
- Connect multimeter between terminals 1 (green/yellow) and 4 (brown)
of harness connector using jumper wires from VW 1594 adaptor kit.
- Press remote control switch continuously and read Voltage.

Specification: approx. Battery Voltage.
- Remove cover flange as follows

- Mark return line -2- and supply line -3- and remove from cover flange.
Pa
ge 34 of 55 Fuel su
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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