AUDI A4 1998 B5 / 1.G Fuel Supply System Biturbo 2.8 User Guide

20-117

- Connect alligator clip to battery (+) .

- Remove fuel filler cap

- Remove engine cover

WARNING!

Fire hazard! Remove everything from the area
that could ignite fuel or fuel vapor. fuel
system is under pressure. Cover connection
with rag and carefully release pressure by
slowly opening the connection.

- Disconnect fuel return line from line connection at fuel distributor.
- Connect test hose -arrow- at fuel distributor line and place other hose
end into measuring cup.
- Operate remote switch for 15 seconds (press button continuously).

*) Volume of fuel delivered in cm
3/15 s - Compare collected fuel with specified value.
Pa
ge 11 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

**)
Voltage at fuel pump with engine not running but pump running
(approx. 2 Volt less than battery voltage).
Pa
ge 12 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-118

Fuel pump, removing and installing


Vehicles with 2.7 ltr. turbo engine
Observe all safety precautions Page 20-1 .
Observe rules of cleanliness Page 20
-4 .

Special tools needed:
Wrench 3217 for threaded cap nut

Wrench 3307 for fuel pump
Pa
ge 13 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-119

Removing

- Obtain radio code for radio with anti-theft
coding.

- Switch off ignition and disconnect battery ground
(GND) cable.

- Briefly open fuel filler cap and then close it
again.

- Empty fuel tank if necessary using fuel
evacuator unit VAG1433 A.


Front wheel drive Page 20
-18
.


All wheel drive Page 20
-66
.

Note:

The fuel tank may not be filled more than
1/3.

- Remove luggage compartment liner.

- Remove cover for fuel pump flange.

WARNING!
Pa
ge 14 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

Fire hazard! Remove everything from the area
that could ignite fuel or fuel vapor. fuel
system is under pressure. Cover connection
with rag and carefully release pressure by
slowly opening the connection.
Pa
ge 15 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-120


- Mark fuel return line -2- and fuel supply line -3- and disconnect from
flange.
- Unclip 4-pin connector -1- and disconnect connector.

- Remove threaded cap nut with wrench 3217.
- Remove fuel pump flange and seal from fuel tank opening.
- On inside of flange disconnect connector for fuel gauge sender.
- Disconnect fuel return line on inside of flange (press release tabs).
Pa
ge 16 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-121


Installing
Installation is in reverse order of removal, but do the following:
Note:
Secure all hose connections with hose clamps identical to factory-installed
clamps.
Parts catalog. - Insert wrench 3307 through fuel tank opening and place on inner part
of fuel accumulator housing.
-
Turn wrench 3307 approx. 15 to the left to stop and remove fuel
pump with inner part of fuel accumulator housing. - Install inner fuel accumulator housing, fuel supply hose and fuel pump
flange in fuel tank.
Pa
ge 17 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-122


Note:
The fuel accumulator housing is shown in the illustration without fuel tank. - Install outer fuel accumulator housing in fuel tank by aligning notch -1-
on inner accumulator housing with notch -2- at outer accumulator
housing.
The inner accumulator housing can be pushed down noticeably.
- Apply wrench 3307 and turn inner fuel accumulator housing with pump
approx. 15 to the right to stop. Notch -1- is then aligned with marking
-3- (bayonet-type connection).

Note:
Lubricate O-rings with fuel before installing. - When installing, turn flange to the right (direction of arrow).
- Connect fuel return line on the inside of flange.
Pa
ge 18 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-123

- Wrap wire for fuel gauge sensor around fuel
supply line (inside fuel tank) and connect to
flange.

- Seal for flange must be dry when inserted in
opening of fuel tank.

Note:
-Arrow 3- applies for vehicles with front wheel drive. - Insert flange in fuel tank.
Installation position for vehicles with all-wheel drive: -arrow 1- must be
opposite -arrow 2-.

Note:
Check that all fuel line and hose connections are securely seated.
Radio operating manual - Tighten threaded cap nut to 60 Nm with wrench 3217.
- Connect wiring and connector.
- After reconnecting the battery enter radio anti-theft code.
Pa
ge 19 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4

20-124

- Move power windows up to stop.

- Then operate power window closing switches
again for at least 1 second to activate the
automatic up-and-down run.

- Adjust time clock.

- Activate readiness code:

Repair Manual, Fuel Injection & Ignition,
Repair Group 01
Pa
ge 20 of 25 Fuel su
pp
ly system, servicin
g (vehicles with 2.7 ltr. turbo 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.GE04.20.4