2000 AUDI A4 Fuel Supply System Biturbo 2.8 Workshop Manual

20-121


Installing
Installation is in reverse order of removal, but do the following:
Note:
Secure all hose connections with hose clamps identical to factory-installed
clamps.
Parts catalog. - Insert wrench 3307 through fuel tank opening and place on inner part
of fuel accumulator housing.
-
Turn wrench 3307 approx. 15 to the left to stop and remove fuel
pump with inner part of fuel accumulator housing. - Install inner fuel accumulator housing, fuel supply hose and fuel pump
flange in fuel tank.
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20-122


Note:
The fuel accumulator housing is shown in the illustration without fuel tank. - Install outer fuel accumulator housing in fuel tank by aligning notch -1-
on inner accumulator housing with notch -2- at outer accumulator
housing.
The inner accumulator housing can be pushed down noticeably.
- Apply wrench 3307 and turn inner fuel accumulator housing with pump
approx. 15 to the right to stop. Notch -1- is then aligned with marking
-3- (bayonet-type connection).

Note:
Lubricate O-rings with fuel before installing. - When installing, turn flange to the right (direction of arrow).
- Connect fuel return line on the inside of flange.
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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
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20-124

- Move power windows up to stop.

- Then operate power window closing switches
again for at least 1 second to activate the
automatic up-and-down run.

- Adjust time clock.

- Activate readiness code:

Repair Manual, Fuel Injection & Ignition,
Repair Group 01
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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
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20-126

Test sequence

- Remove luggage compartment liner.

- Remove cover for fuel pump.

- Unclip 4-pin connector and disconnect.

If the fuel tank contains fuel, the measured value must be between the
specified values for full and empty. - Measure resistance at both terminals -2- and -3- at fuel pump flangeSender
Tank full
Tank empty
Sender for fuel gauge -G
40
280
Pa
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p://127.0.0.1:8080/audi/servlet/Dis
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20-127

-
If you measure 0 (continuity) or (no
continuity), check for open circuit inside the tank
or for short circuit.
Note:
To check resistance for "tank full" or "tank empty"
you must move the float for fuel gauge sender to
upper or lower stop. Removing sender Page
20
-128

Pa
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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
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ly system, servicin
g (vehicles with 2.7 ltr. turbo en
gine
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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