1996 AUDI A4 warning

20-66

Fuel tank, draining


Vehicles with all wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine

WARNING!

Fire hazard! Do NOT have anything in the
area that can ignite gasoline!
Observe Safety measures Page 20
-1 .
Observe Rules of cleanliness Page 20
-4 .

Required equipment

FM 3000 fuel storage cart (or equivalent)
Pa
ge 14 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

20-68

WARNING!

Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.

- Mark return line -2-, supply line -3- and remove cover flange.
- Unlatch and disconnect 4-pin harness connector -1-.

- Unscrew union nut using 3217 wrench.
- Remove cover flange and sealing ring from fuel tank opening.
- Pump remaining fuel through the flange opening.
Pa
ge 16 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

20-69

Fuel tank assembly, removing and
installing


Vehicles with all wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine

WARNING!

Fire hazard! Do NOT have anything in the
area that can ignite gasoline!
Observe Safety measures Page 20
-1 .
Observe Rules of cleanliness Page 20
-4 .

Required special tools, testing equipment
and auxiliary equipment

VAG1359/2 Universal holder
VAG1383 A Engine and transmission jack
Pa
ge 17 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

20-70

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
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

20-72

WARNING!

Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.

- From bottom of vehicle, mark supply line -1-, return line -3- and bleed
line to EVAP canister and disconnect -2-.
- Remove the EVAP canister cover near bottom of spare wheel well
Page 20
-130
.

- Loosen hose connections -1- and -2- on bleed lines.
- Unclip line from bracket -arrow-.
- Place VAG1383A engine and transmission jack under the fuel tank for
support.
- Mark installed position of the clamp bands.
Pa
ge 21 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

20-85


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.
Pa
ge 34 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

20-89

WARNING!

Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.

Vehicles with 1.8 ltr. turbo engine

Vehicles with 2.8 ltr. engine - Disconnect fuel return hose from connection on fuel distributor line.
- Connect auxiliary hose -arrow- to distributor line and place in a
measuring container.

- Disconnect fuel return hose from the hose connection on the fuel
distributor line.
- Connect auxiliary hose -arrow- to distributor line and place in a
measuring container.
Pa
ge 38 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

20-93

WARNING!

Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.

- Mark return line -2- and supply line -3- and disconnect from cover
flange.
- Unlatch and disconnect 4-pin harness connector -1-.

- Unscrew union nut using 3217 wrench .
- Remove cover flange and sealing ring from fuel tank opening.
- Disconnect fuel level display harness connector on inside of flange
cover.
- Disconnect return line on inside of cover flange (press unlatching
buttons).
Pa
ge 42 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