2000 AUDI A4 Fuel Supply System Front Wheel Drive 1.8T And 2.8 Workshop Manual

20-45


Note: - When installing, turn the cover flange in direction of arrow as shown in
illustration.
- Connect the return line inside on the cover flange.
Always use new O-rings. Lubricate O-rings with fuel or coat with a lubricant.Place the new gasket (dry) for the cover flange into the opening of the
fuel tank.
- Wrap sender for fuel gauge -G wiring once around the supply line (in
fuel tank) and install on cover flange.
Pa
ge 41 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

20-46


Note:
-Arrow 1- applies to vehicles with All-Wheel Drive (Not applicable). - Connect cover flange to fuel tank
Installation for vehicles with Front-Wheel Drive: -arrow 2- must be
opposite -arrow 3-.

Note:
Ensure that hose guide (item 7 Page 20
-28
) is kept in position while
tightening the union nut. - Tighten union nut with 3217 wrench.
60 Nm
- Connect wiring and harness connector.
Pa
ge 42 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

20-47

Note:
Ensure that fuel hoses fit tight.

- Connect Ground strap to Battery with ignition
switched OFF.

- After connecting Battery, input radio anti-theft
code

Radio operating instructions
- Run door windows up to stop using the window
switches.

- Operate all window lifters again for at least 1
second in "closed" position to activate automatic
up/down.

- Set the clock.

Tightening torque

Component
Nm
Union nut for cover flange 60
Pa
ge 43 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

20-49


Fuel level between "Tank full" and "Tank empty" must cause a resistance
value that falls between the two specified values.
If 0 or is measured
Note:
To check the resistance values for "Tank full" or "Tank empty" remove the
sender for fuel gauge ( Page 20
-50
) and swing the sensor float to the
top or bottom stop. - Measure resistance at terminals -2- and -3- on cover flange:
Sensor
Tank full
Tank empty
Sender for fuel gauge -G
40
280
There is an open or short circuit in the tank wiring.
Pa
ge 45 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

20-50

Sender for fuel gauge -G, 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 .

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.
- Open fuel tank cover briefly and close again.
- If necessary, drain fuel tank using fuel cart Page 20
-18
.
Pa
ge 46 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

20-51

Note:

The fuel tank must not be filled more than
1/3
maximum.

Fuel supply unit, removing, starting Page 20
-40
.

- Carefully pull cover flange out and push to the
side with hoses connected.

- Disconnect harness connector for fuel level
display on inside of cover flange.

Note:
For clarity, surge housing illustration is shown without tank. - Pull sensor out of surge housing in fuel tank while simultaneously
pressing latching tab -arrow-.
Pa
ge 47 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

20-52

Installing
Installation is performed in the reverse order of
the removal procedure, when installing, note the
following:

- Install the sender for fuel gauge in the guide on
the surge housing outer section and press down
until it engages.

- Wrap sender for fuel gauge wiring once around
return line (in tank).

Cover flange, installing Page 20
-45
.

- Connect Ground strap to Battery with ignition
switched OFF.

- After connecting Battery, input radio anti-theft
coding.

Radio operating instructions
- Run door windows up to stop with electric
window lifters.

-
Operate all window lifters again for at least 1
Pa
ge 48 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