1996 AUDI A4 fuel pump

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-.
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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.
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20-86


- Unscrew union nut using wrench 3217.
- Take cover flange and sealing ring out of the fuel tank opening.

If wiring OK - Check wiring between flange and fuel pump for continuity.
- Fuel pump faulty, replace Page 20
-91
.
- Fuel supply unit, installing Page 20
-96
.
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gine
)
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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.
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)
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20-90

All vehicles

- Operate remote control for 15 seconds.

Keep button depressed continuously

*) Minimum supply quantity cm
3/15 s
**)
Voltage across fuel pump with engine off and pump running (approx. 2
Volts less than Battery Voltage). - Compare delivered quantity to specified value.
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)
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20-91

Fuel supply unit, 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 .

Required special tools, testing equipment
and auxiliary equipment

FM 3000 fuel cart (or equivalent)
3217 Union nut wrench
3307 fuel pump wrench
VAG1275 Hose clamp pliers
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20-94


- Insert 3307 wrench through fuel tank opening and place over the inner
section of the surge housing.
-
Using 3307 wrench, turn inner section of surge housing approx. 15 to
the left up to the stop and withdraw fuel pump assembly complete with
the inner housing section.
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)
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20-95

Cover flange and surge housing inner
section, pre-assembling
If cover flange and supply unit were separated

- Pre-assemble parts Page 20
-78
.

Note:
Install a toothed washer beneath each nut.
Angle position, cover flange to inner section of surge housing: 10
- Press together clamps for supply line (between pump and cover flange)
with VAG1275 pliers.
- Attach wiring to fuel pump.
M4: 1.5 Nm M5: 2 Nm
- Attach wiring with fuel-resistant cable ties.
Pa
ge 44 of 55 Fuel su
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ly system, servicin
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gine
)
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE04.20.3