1996 AUDI A4 fuel cap

20-109


7 -
Fuel pump flange
Can only be installed together with fuel
pump. Removing and installing Page 20
-118
Installation position: Note arrow Page 20
-123

8 -
Connector
For fuel pump and sender for fuel gauge -G
9 -
Threaded cap nut - 60 Nm
Pa
ge 3 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

20-114
If specified value was obtained even so you
could not hear the fuel pump run, remove the fuel
pump flange as follows:

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.

- Mark fuel return line -2- and fuel supply line -3- and remove from fuel
pump flange.

- Remove threaded cap nut with wrench 3217.
- Lift flange and seal from tank opening.
Pa
ge 8 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

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

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

20-123

- 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