1996 AUDI A4 engine

20-107


Fuel supply system, servicing
(vehicles with 2.7 ltr. turbo
engine) WARNING!
Always comply with all applicable safety
precautions when working on the fuel system
Note:

Always replace gaskets, seals and hose clamps
when working on the fuel system.
Hose connections are secured either with
screw-type or spring-type clamps. Always
replace clamps with factory clamps, see Parts
catalogue.
1 -
Sender for fuel gauge -G
Ball-shaped floatCheck resistance Page 20
-125
Removing and installing Page 20
-128
Pa
ge 1 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

20-111


Fuel pump, checking electrically

Vehicles with 2.7 ltr. turbo engine
Special tools needed:

VAG3217
VAG1348/3A with VAG1348/3-2
VAG1526 A
VAG1594 A
Pa
ge 5 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

20-116

Fuel pump delivery volume, checking


Vehicles with 2.7 ltr. turbo engine

Special tools needed:
Test conditions:
Test sequence
Remote switch VAG1348/3A with adapter wire VAG1348/3-2Measuring cupBattery voltage at least 12 V Fuel filter OK Ignition switched off.
- Open fuse panel cover at left side of instrument panel.
- Remove fuse 28 from fuse panel (left row, fifth. large fuse from the
top).

- Connect remote switch VAG1348/3A with adapter wire VAG1348/3-2 to
right terminal of fuse socket 28 -arrow-.
Pa
ge 10 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

20-117

- 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

20-125

Sender for fuel gauge -G, checking


Vehicles with 2.7 ltr. turbo engine

Note:
To check the signal/wiring between the sender -
G and the fuel gauge:

Repair Manual, Electrical Equipment, Repair
Group 90


Special tools needed:
VAG1526 A

VAG1594 A
Pa
ge 21 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

20-128

Sender for fuel gauge -G, removing and
installing


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

Removing

- Fuel pump flange, removing Page 20
-118
.

- Carefully lift out fuel pump flange with fuel
supply line connected and set aside.

- On the inside of the fuel pump flange disconnect
connector for fuel gauge sender.

Note: - Remove sender by pressing tab -arrows-.
The fuel accumulator housing is shown in the illustration without the
fuel tank. The illustration shows the fuel gauge sender for vehicles with front
wheel drive.
Pa
ge 24 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