ignition 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
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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

20-67

CAUTION!

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

- Disconnect Battery Ground strap.
Ensure that ignition is switched OFF.
- Remove cover from fuel filler neck.
- Empty as much fuel as possible through the filler neck.
- Remove connector flange cover under luggage compartment trim.
Pa
ge 15 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

20-70

Removing

CAUTION!

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

WARNING!
Empty the fuel tank before removing it! If it is not empty, the weight
and sloshing fuel could lead to injury, component damage or
possible fuel spillage. - Disconnect Battery Ground strap.
First ensure that ignition is switched OFF.
- Open fuel tank cover briefly and close again.
- If necessary, drain fuel tank using fuel cart Page 20
-66
.
Pa
ge 18 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

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.
Pa
ge 25 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

20-81


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
Pa
ge 30 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

20-83

Test requirements

Battery Voltage: 12 Volts minimum

Fuse 28 OK

Relay 6 in Fuse / Relay panel OK Fuel filter OK Ignition switched OFF.
Pa
ge 32 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

20-87

Fuel pump delivery volume, 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 with VAG1348/3-
2 adaptor cable
Calibrated measuring container

Test requirements
Battery Voltage: 12 Volts minimum
Fuel filter OK
Ignition switched OFF.
Pa
ge 36 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

20-92

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.
Pa
ge 41 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

20-98


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.
Pa
ge 47 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

20-101

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