1999 AUDI A4 engine

20-27


Fuel supply unit and sender for fuel gauge
-G, component overview

Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Sealing ring
-Replace
Installing: insert (dry) into fuel tank opening
2 -
O-rings
- Always replace.
- Check installation position
3 -
Return line From fuel distributor
- Mark before removal
- Note direction of arrow on connecting
flange
4 -
Supply line To fuel distributor
- Mark before removal
- Note direction of arrow on connecting
flange
Pa
ge 23 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2

20-31

Fuel pump, electrical checking


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

Required special tools, testing equipment
and auxiliary equipment

VAG1348/3A Remote control using
VAG1348/3-2 adaptor cable
Fluke 83 multimeter
VW 1594 Adaptor kit
Pa
ge 27 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2

20-36

Fuel pump delivery volume, checking


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

Required special tools, testing equipment
and auxiliary equipment

VAG1348/3A Remote control using
VAG1348/3-2 adaptor cable
Calibrated measuring container

Checking requirements
Battery Voltage: 12 Volts minimum
Fuel filter OK
Ignition switched OFF.
Pa
ge 32 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2

20-37

Test sequence

- Open fuse box cover on left side of instrument
panel.

- Remove fuse 28 from fuse holder (left row, 5Th
fuse from top).

- Connect remote control to right side of fuse 28 holder using adaptor
cable -arrow-.
- Connect tester lead to Battery +.
- Remove fuel filler cap.
- Remove engine cover.
Pa
ge 33 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2

20-38

Vehicles with 1.8 ltr. turbo engine

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 2.8 ltr. engine
WARNING!
Fuel system is under pressure! Before opening, place clean cloths
around the connections to be opened. Carefully loosen the
connections to relieve pressure. - Disconnect fuel return hose from connection on fuel distributor line.
- Connect auxiliary hose -arrow- to distributor line and hold in measuring
container.

- Disconnect fuel return hose from hose connection on fuel distributor
line.
- Connect auxiliary hose -arrow- to distributor line and hold in measuring
container.
Pa
ge 34 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2

20-39

All vehicles

- Operate remote control for 15 seconds.

Press remote button continuously

*) Minimum supply quantity cm
3/15 s
**)
Voltage on fuel pump with engine off and pump running (approx. 2
Volts less than Battery Voltage). - Compare fuel quantity pumped to specified value.
Pa
ge 35 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2

20-40

Fuel supply unit, removing and
installing


Vehicles with front 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

3217 Union nut wrench
3307 fuel pump wrench
VAG1275 Hose clamp pliers

Removing

CAUTION!

Obtain the radio Anti-theft code from the
customer before disconnecting the Battery
Ground strap.

- Disconnect Battery Ground strap with ignition switched OFF.
Pa
ge 36 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2

20-48

Sender for fuel gauge -G, checking


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

Note:
Checking signal between sender for fuel gauge -
G and fuel gauge.

Repair Manual, Electrical Equipment, Repair
Group 90


Required special tools, testing equipment
and auxiliary equipment

Fluke 83 Multimeter
VW 1594 Adaptor kit

- Remove connector flange cover under luggage
compartment trim.

- Unlatch and disconnect 4-pin harness connector -1-.
Pa
ge 44 of 49 Fuel su
pp
ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. 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.GE04.20.2