Audi Fuel System

Service
Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
Fuel supply system, petrol engines
Engine ID ALZ ALT AML AMM ASN AVJ AWA BBJ BBK
BDV BEX BFB BGB AUK AMB AVK BGN BNS
BPJ BKB BUL BWE BHF
Edition 04.2017
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
20 - Fuel supply system
Technical information
Protected by should always
copyright. Copying beoravailable
for private to the
commercial purposes, foremen
in part or in whole, isand
not mechanics, because their
careful and constant
permittedadherence
unless authorisedto the AG.
by AUDI instructions
AUDI AG does not is guarantee
essential to ensure
or accept any liability vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Audi AG, Ingolstadt A0059006220

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
Fuel supply system, petrol engines - Edition 04.2017
Contents
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Notes for working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Fuel tank on all front-wheel drive vehicles with MPI and 2.0 ltr. FSI engine . . . . . . . . . . . . 3
2.1 Exploded view - fuel tank with components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Exploded view - fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Checking fuel pump (electrical test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Checking fuel pump delivery rate - vehicles with 4-cylinder naturally aspirated engine . . . . 16
2.7 Checking fuel pump delivery rate - vehicles with 1.8 ltr. turbo engine . . . . . . . . . . . . . . . . 18
2.8 Checking fuel pump delivery rate - vehicles with 4-cylinder FSI engine . . . . . . . . . . . . . . 20
2.9
Protected Checking fuel pump
by copyright. Copying for privatedelivery rate
or commercial - vehicles
purposes, in part orwith 6-cylinder
in whole, is not MPI engine . . . . . . . . . . . . . . 22
2.10
permitted Removing
unless authorisedand installing
by AUDI AG. AUDIfuel
AG doesdelivery unitor accept
not guarantee . . . . any
. . liability
................................ 23
2.11 Checking fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.12 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3 Fuel tank on front-wheel drive vehicles with 4-cylinder TFSI and 6-cylinder FSI engine . . 31
3.4 Exploded view - fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6 Checking fuel pump control unit J538 - vehicles with 4-cylinder TFSI engine . . . . . . . . . . 43
3.7 Checking fuel pump control unit J538 - vehicles with 6-cylinder FSI engine . . . . . . . . . . . . 47
3.8 Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine . . . . . . . . . . . . . . 47
3.10 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.11 Adapting fuel pump after renewing fuel delivery unit - vehicles with 4-cylinder TFSI engine
........................................................................ 56
4 Fuel tank on vehicles with four-wheel drive - vehicles up to 10.2004 . . . . . . . . . . . . . . . . 62
4.4 Exploded view - fuel delivery unit and fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7 Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine . . . . . . . . . . . . . . 78
4.8 Checking fuel pump delivery rate - vehicles with 8-cylinder MPI engine . . . . . . . . . . . . . . 80
4.12 Checking fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.13 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.14 Suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.15 Removing and installing suction-jet pump in left fuel tank chamber . . . . . . . . . . . . . . . . . . 97
5 Fuel tank on vehicles with four-wheel drive - vehicles from 11.2004 onwards . . . . . . . . . . 106
Contents i
5.4 Exploded view - fuel delivery unit and fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . . . 116
5.6 Checking fuel pump control unit J538 - vehicles with 4-cylinder TFSI engine . . . . . . . . . . 121
5.7 Checking fuel pump control unit J538 - vehicles with 6-cylinder and 8-cylinder FSI engine
........................................................................ 125
5.8 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.10 Checking fuel pump delivery rate - vehicles with 4-cylinder TFSI engine . . . . . . . . . . . . . . 131
5.11 Checking fuel pump delivery rate - vehicles with 6-cylinder MPI engine . . . . . . . . . . . . . .
134
5.12 Checking fuel pump delivery rateauthorised
permitted unless - vehicles with
by AUDI AG.6-cylinder
AUDI AG doesFSI engineor accept
not guarantee . . . any
. .liability
......... 135
5.13 Checking fuel pump delivery rate - vehicles with 8-cylinder MPI engine . . . . . . . . . . . . . .
138
5.16 Adapting fuel pump after renewing fuel delivery unit - vehicles with 4-cylinder TFSI engine
........................................................................ 148
5.19 Checking fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.20 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.21 Suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.22 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6 Servicing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.1 Removing and installing fuel filter - fuel system with fuel return line . . . . . . . . . . . . . . . . . . 165
6.2 Removing and installing fuel filter - fuel system without fuel return line . . . . . . . . . . . . . . . . 166
6.3 Removing and installing fuel filter - vehicles with 1.8 ltr. turbo engine with front-wheel drive
(all versions) or with four-wheel drive up to 10.2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.1 Vehicles with 1.8 ltr. turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8 Servicing components of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.1 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
9 Servicing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.1 Exploded view - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.2 Removing and installing accelerator pedal module with accelerator position sender . . . . 173
9.3 Adapting kick-down function after renewing accelerator pedal position sender or engine
control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
ii Contents
20 – Fuel supply system

1 Notes for working on fuel supply sys‐
tem
(ARL005198; Edition 04.2017)
1.1 Safety precautions when working on the

fuel supply system
WARNING
The fuel system is pressurised. Before opening the system

place a clean cloth around the connection. Then carefully loos‐
en the connection to relieve the pressure.
Perform the following steps before starting to work on the fuel

supply system:
Caution
Observe notes on procedure for disconnecting the battery ⇒

Rep. gr. 27 .
♦ With ignition switched off, disconnect earth strap from battery.

♦ Briefly open filler cap for fuel tank and close again.
When removing and installing components from a full or partly full
fuel tank, note the following:
♦ Fuel tank must not be full. The amount of fuel which can be
left in the tank is indicated in the corresponding procedure de‐
scription. Drain the tank if necessary.
♦ Before commencing work, switch on exhaust extraction sys‐
tem and place an extraction hose close to the opening in the
fuel tank to extract escaping petrol fumes. If no exhaust ex‐
traction system is available, a radial fan with a displacement
of at least 15 m3/h can be used (the fan motor must be clear
of the air stream).
♦ Avoid skin contact with fuel. Wear fuel-resistant gloves.
When removing and installing fuel tank, note the following:
♦ Fuel tank must be empty to reduce weight. Drain the tank if
necessary.
♦ Procedure for draining the fuel system: Front-wheel drive ve‐
hicles with MPI and 2.0 litre FSI engine ⇒ page 4 , front-
wheel drive vehicles with 4-cylinder TFSI and 6-cylinder FSI
engine ⇒ page 32 , four-wheel drive vehicles up to 10.2004
⇒ page 63 , four-wheel drive vehicles from 11.2004 onwards
⇒ page 107 .
1.2 Rules for cleanliness

When working on the fuel supply/injection system, paydocument.

carefulCopyright
at‐ by AUDI AG.
with respect to the correctness of information in this
tention to the following rules:
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before disconnecting.
1. Notes for working on fuel supply system 1

♦ After removal, place parts on a clean surface and cover them.

Only use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use any
parts that have been unpacked previously and stored away
loosely (e.g. in a tool box).
♦ Do not work with compressed air when the system is open. If
possible, do not move vehicle.
2 Rep. gr.20 - Fuel supply system

2 Fuel tank on all front-wheel drive ve‐

hicles with MPI and 2.0 ltr. FSI engine
2.1 Exploded view - fuel tank with components
Note
The illustration shows a fuel system with fuel return line.
1 - Fuel supply line

❑ From fuel filter
❑ To engine Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Do not kink permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Press release tab on
connection piece to dis‐
connect
2 - Fuel return line
❑ From engine
❑ Do not kink
connect
❑ Clip onto fuel tank
3 - Breather line
❑ Leading to activated
charcoal filter in wheel
housing (front right)
❑ Do not kink
connect
4 - 23 Nm
❑ Secures fuel filler neck
and earth connection
⇒ Item 10 (page 3)
5 - Overflow hose
❑ Attach to wheel housing
6 - Rubber cup
7 - Tensioning ring
8 - Seal
❑ Renew if damaged
9 - Filler cap
❑ Secured to tank flap
10 - Earth connection
❑ To eliminate electrostatic charge
❑ Installation position / test procedure ⇒ page 4
❑ Ensure that connector is seated properly and secure wire with securing bolt for fuel filler neck
⇒ Item 4 (page 3)
2. Fuel tank on all front-wheel drive vehicles with MPI and 2.0 ltr. FSI engine 3
❑ After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel
filler neck and a bare metal part on the body. Specification: approx. 0 Ω
11 - Breather line
12 - Fuel tank
❑ Removing and installing ⇒ page 6
13 - Heat shield
❑ For fuel tank
14 - 2 Nm
15 - Heat shield
❑ For fuel tank
16 - 2 Nm
17 - Fastener
18 - Securing strap
❑ Note different lengths
19 - 23 Nm
Installation position of earth connection

– Route earth connection as shown in illustration.
– Hook earth connection contact -1- into mounting hole on fuel
tank -4-.
– Ensure that connector -3- for earth connection is firmly seated
on metal ring -2- on fuel filler neck.
Caution
After installation, use an ohmmeter to check the electrical con‐

nection between the metal ring on the fuel filler neck and a bare
metal part on the body:
• Specification: approx. 0 Ω.
2.2 Draining fuel tank

Special tools and workshop equipment required
♦ Fuel extractor - VAS 5190-

Procedure
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 1 .
Caution

Rep. gr. 27 .
– Push battery cover to the right -arrow 1- and lift it off

-arrow 2-.
– With ignition switched off, disconnect earth strap -arrow- at

battery.
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part on the body.
– Detach tapered adapter -2- from shaft end -1- of fuel extractor
- VAS 5190- .
– Use insulating tape to mark extraction hose -arrow- at a dis‐
tance of -a- = 1,465 mm from end of hose.
– Remove filler cap from fuel filler neck.

– Screw shaft end -1- of fuel extractor - VAS 5190- onto fuel filler
neck.
– Push extraction hose into fuel tank until marking on extraction
hose -arrow- coincides with shaft end.
Note
♦ The procedure when using a fuel extractor without shaft end

is basically the same.
♦ In this case, make a mark -arrow- on the extraction hose at
distance -a- = 1,400 mm from the end of the hose using insu‐
lating tape. The extraction hose has been properly inserted
when the affixed mark is level with the edge of the filler neck.
♦ If hose is difficult to insert, apply a thin coat of engine oil. DO
NOT use silicone-based lubricant.
– Drain fuel tank via fuel filler neck.

– Carefully remove extraction hose.
2.3 Removing and installing fuel tank with

attached components
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing
• To reduce weight, the fuel tank must be empty when it is re‐
moved from the vehicle. Drain the tank if necessary. Proce‐
dure ⇒ page 4
Caution

Rep. gr. 27 .

-arrow 2-.


battery.
– Briefly open filler cap for fuel tank and close again.
Saloon:
– Detach trim in luggage compartment.
– If necessary, fold forward right backrest of rear seat bench.
Avant:
– Remove left-side section of backrest (1/3 section) ⇒ Rep. gr.
72 .
– Remove left-side trim in luggage compartment and anti-soiling
tray ⇒ Rep. gr. 70 .
Both types:
– Unscrew cover for flange -arrows-.
– Unplug electrical connector -arrow- at flange.
Vehicles with hose connection:

– Detach breather line -1-.
Vehicles with plug-in connector:

– Press release tab -arrow- and disconnect breather line.
Both types:
– Open tank flap and detach loop -1- on tank flap.
Note
Do not remove filler cap.
– Clean area around fuel filler neck.

– Lever off retaining ring -arrow- in rubber cup and press rubber
cup through to inside.
– Remove rear wheel (right-side).

– Remove rear right wheel housing liner ⇒ Rep. gr. 66 .
– Disconnect breather line -2- from fuel filler neck.
– Unscrew bolt -1- for fuel filler neck.
– Remove trim panel on underbody -arrows-.

– Remove underbody covers -1- and -2-.

– Remove rear section of exhaust system ⇒ Rep. gr. 26 .
WARNING
BEFORE loosening subframe bolts, take steps to ensure that

vehicle does not tip forwards (e.g. put a weight of about 50 kg
in luggage compartment).
– Remove rear axle ⇒ Rep. gr. 42 .
– Disengage handbrake cable from front right of fuel tank at

points marked by -arrows-.
WARNING

– Detach fuel supply line -1- from fuel filter (press release tab).
Catch escaping fuel.
– Disconnect fuel return line -3- and breather line -2- at connec‐
tion (press release tab). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– On vehicles with auxiliary heater, also disconnect fueltoline
with respect the correctness of information in this document. Copyright by AUDI AG.
leading to metering pump for auxiliary heater.
Vehicles with 1.8 ltr. turbo engine:
WARNING

– Disconnect fuel line -1- and breather line -2- from front right of
fuel tank by pressing release tabs.
– On vehicles with auxiliary heater, also disconnect fuel line
All vehicles:
– Position engine and gearbox jack - V.A.G 1383 A- below ve‐
hicle to support tank.
WARNING
To reduce weight, fuel tank must be empty upon removal.
– Remove bolts -1 ... 7-.

– Then lower fuel tank using engine and gearbox jack - V.A.G
1383 A- .
Installing
Installation is carried out in the reverse order; note the following:
Note
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .
– Check that fuel linespermitted
and breather lines are clipped onto brack‐
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ets and fuel tank -arrows-.

– Check the earth wiring at both ends for traces of oxidation.

Remove any traces of oxidation if necessary.
– Check installation position of earth connection:
• Connector -3- must be seated securely on metal ring -2-.
• The contact tab -1- must be hooked onto the fuel tank -4-.
– Position fuel tank with securing straps on underbody using

engine and gearbox jack - V.A.G 1383 A- .
– When installing fuel tank, make sure that the fuel filler neck is
correctly inserted into the opening on the body.
– Secure fuel tank by first tightening bolts at points -2, 5, 3, 4-,
then at points -1, 6, 7-.
– Secure fuel filler neck.
Caution

– Install rear axle ⇒ Rep. gr. 42 .

– Install rear section of exhaust system ⇒ Rep. gr. 26 .
– Install rear right wheel housing liner and tighten securing bolt
for fuel filler neck ⇒ Rep. gr. 66 .
– Connect battery. Observe notes on procedures required after
connecting battery ⇒ Rep. gr. 27 .
Tightening torques
Component Nm
Securing straps to body 23
Fuel filler neck to wheel housing 23
2.4 Exploded Protected

view byunless
permitted - copyright.
fuel delivery
by AUDI AG.unitAUDIand fuel
AG does gauge
not guarantee sender
Copying for private or commercial purposes, in part or in whole, is not
authorised or accept any liability
Note
Illustration shows fuel delivery unit on vehicles with 6-cylinder engine.
1 - Fuel gauge sender - G-

❑ Checking resistance
values ⇒ page 28
❑ Removing and installing
⇒ page 30
2 - Fuel delivery unit
❑ Checking fuel pump
(electrical test)
⇒ page 13
❑ On vehicles with 4-cylin‐
der FSI engine with in‐
tegrated fuel pressure
regulator ⇒ page 13
❑ Checking residual pres‐
sure ⇒ Rep. gr. 24
⇒ page 23
❑ Put at least 5 litres of
fuel into tank after instal‐
ling
3 - Seal
❑ Renew
❑ Install dry
❑ Mark before removing
connect
❑ Do not kink
❑ Note direction of arrow
(fuel supply or fuel re‐
turn system) on flange
when installing
5 - Fuel supply line Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Mark before removing with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Press release tab on connection piece to disconnect
❑ Do not kink
❑ Note direction of arrow (fuel supply or fuel return system) on flange when installing
6 - Electrical connector
❑ For fuel gauge sender - G-
❑ For fuel system pressurisation pump - G6-
7 - Union nut, 80 Nm
❑ Depending on version, remove and install using union nut tool - 3217- or key - T10202-
8 - Supply line for suction-jet pump
9 - Suction-jet pump
❑ On vehicles with auxiliary heater (from approx. 02.2003 onwards) suction pipe for auxiliary heater runs
along suction pipe for suction-jet pump ⇒ page 13

Fuel delivery unit with integrated fuel pressure regulator

On vehicles with 4-cyl. FSI engine, fuel pressure regulator
-arrow- is integrated in fuel delivery unit. It is not possible to de‐
tach fuel pressure regulator from fuel delivery unit.
Suction pipe on vehicles with auxiliary heater from approx.

02.2003 onwards
From approx. 02.2003 onwards the suction pipe -1- for the auxil‐
iary heater is routed along the suction pipe for the suction-jet
pump and is connected with the fuel delivery unit via a connection
piece -2-.
2.5 Checking fuel pump (electrical test)
Special tools and workshop

equipment required
♦ Remote control - V.A.G 1348/3A- for V.A.G 1348 with adapter

cable - V.A.G 1348/3-2-
♦ Hand-held multimeter - V.A.G 1526C-
♦ Auxiliary measuring set - V.A.G 1594C-
Procedure
• Battery voltage at least 12.5 V
• Fuse in fuse holder - S228- (position 28) OK.
• Fuel pump relay - J17- -arrow- OK (located at plug-in position
No. 1 in nine-way relay carrier behind storage compartment
on driver's side).
• Fuel filter OK.
• Ignition switched off.

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

– Take out fuse in fuse holder - S228- (left row, 5th large fuse
from the top).
– Connect remote control - V.A.G 1348/3A- for V.A.G 1348 with
adapter cable - V.A.G 1348/3-2- to right-hand terminal on
socket of fuse -S228- .
– Connect crocodile clip to positive (+) terminal of battery.
– Press remote control button.
• Pump should start running audibly.
Note
The fuel pump runs very quietly. Where possible, avoid noisy sur‐
roundings for this test.
If no noise can be heard from pump:

Saloon:
Avant:
72 .
– Remove left-side trim unless
permitted in luggage
authorisedcompartment
by AUDI AG. AUDI andAG doesanti-soiling
not guarantee or accept any liability
tray ⇒ Rep. gr. with
70 respect
. to the correctness of information in this document. Copyright by AUDI AG.
Both types:
– Connect hand-held multimeter - V.A.G 1526C- between con‐

tacts -1- and -4- to measure voltage.
• Specification: approx. battery voltage
If specification is not obtained:
– Eliminate open circuit in wiring (refer to current flow diagram).
If reading matches specification although no noise can be heard

from pump:
– Remove fuel delivery unit ⇒ page 23 .
– Check that the electrical wires between flange and fuel pump
are connected and test for continuity.
If no fault is found in wiring, fuel pump is defective. Renew fuel
delivery unit.
– Install fuel delivery unit ⇒ page 26 .
2.6 Checking fuel pump delivery rate - vehi‐

cles with 4-cylinder naturally aspirated
engine
cable - V.A.G 1348/3-2-
♦ Fuel-resistant measuring container

Procedure
• Battery voltage at least 12.5 V Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Fuel filter OK. with respect to the correctness of information in this document. Copyright by AUDI AG.
• Fuel tank at least 1/4 full

• Fuel pressure regulator OK; checking ⇒ Rep. gr. 24


from the top).

– Remove engine cover panel -arrows-.
WARNING

– Disconnect fuel return hose -1- from pipe connection on fuel

rail.
Note
Disregard -item 2-.
– Fit auxiliary hose -arrow- onto fuel rail and hold end of hose in
measuring container.
– Press remote control button for 15unless
permitted seconds.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Compare amount of fuel delivered with minimum delivery

shown in diagram (cm3/15 sec.).
Note
Voltage at fuel pump with engine stationary and pump running is

approx. 2 volts less than battery voltage.
Assembly is carried out in the reverse order; note the following:
Note
– Connect fuel return hose.

cles with 1.8 ltr. turbo engine
♦ Adapter -V.A.G 1318/17-1- from adapter set - V.A.G 1318/17-

cable - V.A.G 1348/3-2-

Procedure
• Fuelpermitted
filter OK.


from the top).
Saloon:
Avant:
72 .
Both types:
WARNING

– Disconnect fuel return line -2- by pressing release tab.

Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Disregard -item 1-.
– Fit adapter -V.A.G 1318/17-1- onto disconnected fuel return

line and hold adapter hose in measuring container.
– Press remote control button for 15 seconds.

Note


– Connect fuel return line.

cles with 4-cylinder FSI engine
♦ K-Jetronic pressure tester - V.A.G 1318-
♦ Adapter set - V.A.G 1318/10-12-

cable - V.A.G 1348/3-2-

Procedure
• Fuel filter OK.
from the top).

WARNING

– Disconnect fuel supply line -1- from pipe connection on en‐

gine.
Note
Disregard items -2 ... 5-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect K-Jetronic pressure tester - V.A.G 1318- with adapt‐

ers - V.A.G 1318/11- and -V.A.G 1318/12- to fuel supply line.
– Fit auxiliary hose -arrow- onto pressure tester and hold end of
hose in measuring container.
– Open cut-off valve on pressure tester. Lever must point in di‐
rection of flow.
– Build up pressure in fuel system by pressing remote control
button and slowly closing cut-off valve on pressure tester.
• Specification: 4 bar
– From this point on do not move position of cut-off valve.
– Empty the measuring container.

Note


– Connect fuel line.
Tightening torque
Component Nm
Fuel line to fuel rail 28

cles with 6-cylinder MPI engine
cable - V.A.G 1348/3-2-
♦ Fuel-resistant measuring container Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Procedure

• Fuel filter OK.


from the top).
WARNING

– Disconnect fuel return hose from pipe connection on fuel rail.


Note

Note
2.10 Removing and installing fuel delivery

unit
♦ Union nut tool - 3217-
Removing
• The fuel tank must not be more than 3/4 full when removing
the fuel delivery unit. Drain the tank if necessary. Procedure
⇒ page 4
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Saloon: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Avant:
72 .
Both types:

– Mark fuel supply line -1- and fuel return line -2-.
WARNING

– Detach both lines from flange (press release tabs).

leading to metering pump for auxiliary heater (press release
tab).
WARNING
The fuel tank must not be more than 3/4 full when removing the
fuel delivery unit. Otherwise a large amount of fuel will escape.
– Depending on version, remove union
permitted nutauthorised
unless using union
by AUDI nut toolAG does not guarantee or accept any liability
AG. AUDI
- 3217- or key - T10202- . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pull fuel delivery unit just slightly out of opening in fuel tank
and remove seal.
Vehicles with auxiliary heater from approx. 02.2003:

– Pull connection -2- upwards and disconnect suction pipe for
auxiliary heater (press release tab).
All vehicles:
– Move flange slightly to one side with fuel delivery unit still lo‐
cated in fuel tank.
– Reach into fuel tank in the gap between flange and installation
opening and release suction-jet pump -1-.
Note
Fuel tank is shown in a cut-away view for illustration purposes.
– Pull suction-jet pump -1- upwards with its supply line -2- con‐
nected.
– Disconnect supply line from suction-jet pump (press release
tab).
– Remove suction-jet pump.
– Remove fuel delivery unit.
Note
♦ When removing fuel delivery unit, make sure you do not bend
float arm of fuel gauge sender - G- .
♦ Keep in mind that the fuel delivery unit still contains fuel.
Installing
Note
♦ Renew seal.
♦ When inserting fuel delivery unit, make sure you do not bend
♦ Ensure that fuel hose is securely connected.
– Insert fuel delivery unit in Protected

fuel tank.by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach supply line -2- to suction-jet
with respectpump connection
to the correctness -1-. in this document. Copyright by AUDI AG.
of information

– Clip suction-jet pump -1- onto fuel delivery unit. To do so,

reach into gap between flange and opening in fuel tank.
• The suction-jet pump should click into place.
– Check that suction-jet pump has engaged properly.
Note
Fuel tank isProtected

shownbyincopyright.
a cut-away view
Copying for for
private illustration
or commercial purposes.
purposes, in part or in whole, is not
Vehicles with auxiliary heater from approx. 02.2003:

– Attach suction pipe for auxiliary heater to connection -2-.
All vehicles:
– Install new seal for flange (seal must be installed dry).
– Press flange down against spring pressure, then turn flange
to installation position.
• Arrow -2- on flange must align with arrow -1- on fuel tank.
– Tighten union nut for flange.
– Install fuel supply line -1- and fuel return line -2- (as marked).
– Plug in electrical connector.
– Put at least 5 litres of fuel into tank after installing fuel delivery
unit.
Tightening torque
Component Nm
Union nut for fuel delivery unit 80
2.11 Checking fuel gauge sender - G-


Procedure
Saloon:
Avant:
72 .

Both types:
Vehicles up to 06.2001
– Connect hand-held multimeter - V.A.G 1526C- to measure re‐
sistance between contacts -2- and -3-.
Sender installed Sender at low‐ Sender at up‐
er stop per stop
Fuel gauge sender - G- approx. 65 Ω approx. 275 Ω
Note
♦ If the resistance is 0 Ω, there is a short circuit. If the resistance

is ∞ Ω, there is an open circuit in the wiring.
♦ To test the maximum and minimum resistance values for “tank
full” and “tank empty”, remove the fuel delivery unit
⇒ page 23 and move the sender float all the way to its top or
bottom position.
♦ The following values are obtained with the fuel gauge sender
- G- removed, due to the greater travel of the float arm:
Sender removed Sender at low‐ Sender at up‐

er stop per stop
Vehicles from 06.2001 onwards

er stop per stop
Fuel gauge sender - G- 300 … 310 Ω 53.5 … 59 Ω
Note

bottom position.

er stop per stop
Fuel gauge sender - G- 271 … 296 Ω 55 … 69 Ω
Assemble in reverse order.
2.12 Removing and installing fuel gauge

sender - G-
Removing
Caution
First release retaining tabs on connector contact before un‐

plugging electrical connectors on fuel gauge sender - G- .
– Release retaining tabs on electrical connectors -1- and -2- and

unplug connectors.
– Lift retaining tabs -3- and -4- with a screwdriver and pull fuel
gauge sender - G- off downwards -arrow-.
Installing
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press upwards until it clicks into place.
– Plug in electrical connectors and check that they have engag‐
ed properly.
– Install fuel with
delivery unit
respect to ⇒ page of26
the correctness , observing
information the instructions
in this document. Copyright by AUDI AG.
for connecting the battery ⇒ Rep. gr. 27 .

3 Fuel tank on front-wheel drive vehi‐

cles with 4-cylinder TFSI and 6-cylin‐
der FSI engine
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The illustration shows a fuel system without fuel return line.
1 - Fuel line
❑ To engine
❑ Do not kink
connect
2 - Breather line
❑ Do not kink
connect
3 - 2 Nm
4 - Heat shield
❑ For fuel filler neck
5 - 23 Nm
-item 11-
6 - Overflow hose
❑ Attach to wheel housing
7 - Rubber cup
8 - Tensioning ring
9 - Seal
10 - Filler cap
❑ Ensure that connector is seated properly and secure wire with securing bolt for fuel filler neck -item 5-
3. Fuel tank on front-wheel drive vehicles with 4-cylinder TFSI and 6-cylinder FSI engine 31
12 - Breather line
13 - Fuel tank
14 - Heat shield
❑ For fuel tank
15 - 2 Nm
16 - Heat shield
❑ For fuel tank
17 - 2 Nm
18 - Fastener
19 - Securing strap
❑ Note different lengths
20 - 23 Nm

– First engage contact tab -2- of earth connection in mounting
hole on fuel tank -5- and then press in spacer bush -1- if fitted.
Caution



Procedure
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Caution
part on the body.
- VAS 5190- .

neck.
Note

– Drain fuel tank via fuel filler neck.


attached components

Removing
dure ⇒ page 32
Caution

Rep. gr. 27 .

-arrow 2-.


battery.
Saloon:
Avant:
72 .unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted

Both types:
– Disconnect breather line -1- by pressing release tab on con‐

nection piece.
Note


– Remove rear right wheel housing liner ⇒ Rep. gr. 66 . unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
– Remove trim panel on underbody -arrows-.
– Remove underbody covers -1- and -2-.

WARNING


– Disengage handbrake cable from front right of fuel tank at

points marked by -arrows-.
Fuel system with fuel return line:
WARNING

tion (press release tab). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Vehicles with fuel system without fuel return line - except for 1.8
ltr. turbo engine:
WARNING

– Disconnect breather line -1- and fuel supply line -2- from front
right of fuel tank by pressing release tabs.
WARNING

All vehicles:
WARNING

1383 A- .
Installing
Note
– Check that fuel lines and breather lines are clipped onto brack‐
ets and fuel tank -arrows-.

• Connector -4-
permitted must
unless be seated
authorised securely
by AUDI AG. AUDI AG on
doesmetal ring or-3-.
not guarantee accept any liability
• Contact tab -2- must be attached on fuel tank -5- and secured
with spacer bush -1-, if fitted.

– Position fuel tank with securing straps on underbody using

engine and gearbox jack - V.A.G 1383 A- .
– Secure fuel tank by first tightening bolts at points -2, 5, 3, 4-,
then at points -1, 6, 7-.
Caution

– Install rear axle ⇒ Rep.
permitted gr. 42 by
unless authorised . AUDI AG. AUDI AG does not guarantee or accept any liability
Tightening torques
Component Nm
Securing straps to body 23
3.4 Exploded view - fuel delivery unit and fuel gauge sender

(electrical test)
⇒ page 41
⇒ page 53
ling
values ⇒ page 58
⇒ page 60
3 - Supply line for suction-jet
pump
connect
4 - Seal
❑ Renew
❑ Install dry
connect
❑ Do not kink Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Note direction of arrow with respect to the correctness of information in this document. Copyright by AUDI AG.
(fuel supply or fuel re‐
turn system) on flange
when installing
❑ To fuel filter
❑ Do not kink
8 - Fuel line for auxiliary heater
❑ To metering pump
9 - Locking ring
❑ Depending on version, remove and install using key - T10202- or union nut tool - 3217-
❑ Tighten to 145 Nm

11 - Suction pipe
❑ For auxiliary heater

equipment required

cable - V.A.G 1348/3-3-
Procedure
• Vehicles with MPI engine: Fuel pump relay - J17- -arrow- OK

(located at plug-in position No. 1 in nine-way relay carrier be‐
hind storage compartment on driver's side).
• Vehicles with 4-cylinder TFSI engine: Fuel pump control unit -

J538- must be OK; checking ⇒ page 43 .
• Fuel filter OK.
• Ignition switched off. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Saloon:
Avant:
72 .
Both types:

– Connect remote control - V.A.G 1348/3 A- with adapter cable

- V.A.G 1348/3-3- to contact -1- using a test lead from auxiliary
measuring set - V.A.G 1594C- .
– Tape off 2nd connector contact
permitted unless ofbythe
authorised AUDI adapter
AG. AUDI AGcable
does -not guarantee or accept any liability
V.A.G 1348/3-3- with
with insulating
respect tape -arrow-
to the correctness toinprevent
of information short
this document. Copyright by AUDI AG.
circuits.
– Connect contact -4- to the body (earth) using a test lead from
auxiliary measuring set - V.A.G 1594C- .
Note

delivery unit.
3.6 Checking fuel pump control unit - J538- - vehicles with 4-cylinder TFSI en‐
gine

equipment required

♦ Adapter cable - V.A.G 1598/39-
♦ Test box - V.A.G 1598/42-

Procedure
Checking voltage supply for fuel pump (from fuel pump control
unit - J538- )
Saloon:
Avant:
72 .
– Remove left-side trim in luggage compartment and
AUDIanti-soiling
permitted unless authorised by AUDI AG. AG does not guarantee or accept any liability
tray ⇒ Rep. gr. 70 . with respect to the correctness of information in this document. Copyright by AUDI AG.
Both types:
– Push back protective sleeve.

– Connect hand-held multimeter - V.A.G 1526C- (voltage test
range) with probes and plug-in adapters from auxiliary meas‐
uring set - V.A.G 1594C- between contacts -1- and -4-, as
shown in illustration. The connector remains in place.
Note
The connector contacts are numbered accordingly on the back of

the connector.
– Start engine.
• Specification when starting and at idling speed: approx.
4 ... 5.7 V.
– Press accelerator pedal quickly to the floor and release again
(short throttle burst).
• Specification: The voltage value should first increase slightly,
then drop and eventually rise to the previous reading.
If display differs from specification described above:
– Check voltage supply and activation of fuel pump control unit
-J538- .
Checking voltage supply for fuel pump control unit - J538-

– Unplug electrical connector -arrow- on fuel pump control unit
- J538- .
– Connect multimeter between contacts -3- and -4- of connector

to measure voltage.
– Switch on ignition.
Checking activation of fuel pump control unit - J538-

– Connect multimeter (voltage test range) with probes and plug-
in adapters from auxiliary measuring set - V.A.G 1594C- be‐
tween contacts -4- and -5-, as shown in illustration. The
electrical connector remains in place.
Note

the connector.
– Start engine.
• Specification when starting and at idling speed: approx. 5.0 V.

– Switch off ignition. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Connect the test box - V.A.G 1598/42- to wiring harness with
adapter lead -V.A.G 1598/39-1- or adapter lead -V.A.G
1598/39-2- . Do not connect engine control unit. Connect earth
clip of test box to negative terminal of battery ⇒ Rep. gr. 24 .
Caution
To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector -V.A.G 1598/42-
Contact Socket
-5- B 27
– Repair open circuit or short circuit in wiring (refer to current
flow diagram).
If no fault is found:
– Renew fuel pump control unit - J538- .
3.7 Checking fuel pump control unit - J538-

- vehicles with 6-cylinder FSI engine
The procedure for checking the fuel pump control unit -J538- is
carried out in “Guided Fault Finding” with vehicle diagnostic, test‐
ing and information system - VAS 5051B- .

cles with 4-cylinder TFSI engine
♦ Adapter set - V.A.G 1318/10-12-

cable - V.A.G 1348/3-3-
Procedure
• Fuel pump control unit - J538- OK; checking ⇒ page 43 .

• Fuel filter OK.
Saloon:
Avant:
72 .
Both types:


– Tape off 2nd connector contact of the adapter cable - V.A.G
1348/3-3- with insulating tape -arrow- to prevent short circuits.

WARNING

– Disconnect fuel line -arrow- from pipe connection on engine.

rection of flow.

Note


Tightening torque
Component Nm

♦ Adapter set - V.A.G 1318/10-12-

cable - V.A.G 1348/3-3-


Procedure

• Fuel filter OK.
Saloon:
Avant:
72 .
Both types: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew cover for flange
with respect -arrows-.
to the correctness of information in this document. Copyright by AUDI AG.

– Tape off 2nd connector contact of the adapter cable - V.A.G

– Pull off engine cover panel (rear) -arrows-.
WARNING

– Disconnect fuel line -arrow-.

ers - V.A.G 1318/11- and -V.A.G 1318/12- to fuel line.
rection of flow.


Note

If minimum delivery rate is not reached, check for the following

causes:
♦ Fuel lines have been crushed.
♦ Fuel filter is blocked.
♦ Fuel pump is defective.
Tightening torque
Component Nm

unit
♦ Key - T10202-
Removing
⇒ page 32
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Saloon:
Avant:
72 .
– Remove left-side trim in luggage compartment andauthorised
permitted unless anti-soiling
by AUDI AG. AUDI AG does not guarantee or accept any liability
tray ⇒ Rep. gr. 70 . with respect to the correctness of information in this document. Copyright by AUDI AG.
Both types:
– Mark fuel supply line -1- and fuel return line -3-.
WARNING


-2- leading to metering pump for auxiliary heater (press re‐
lease tab).

WARNING
– Depending on version, remove union nut using union nut tool

- 3217- or key - T10202- .
– Pull fuel delivery unit just slightly out of opening in fuel tank
and remove seal.
– Move flange slightly to one side with fuel delivery unit still lo‐
cated in fuel tank.
– On vehicles with auxiliary heater, pull suction pipe -2- for aux‐
iliary heater out of fuel tank and disconnect (press release tab).
– Reach into fuel tank in the gap between flange and installation
opening and release supply line -1- from suction-jet pump
(press release tab).
– Release suction-jet pump -arrows- and remove.
Note
ProtectedInstalling
by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation
with respect is carried
to the correctness out inin the
of information reverseCopyright
this document. order;bynote the following:
AUDI AG.
Note
♦ Renew seal.
♦ When inserting fuel delivery unit, make sure you do not bend
♦ Ensure that fuel hoses are securely seated.
– Insert fuel delivery unit in fuel tank.
– Clip suction-jet pump onto fuel delivery unit. To do so, reach

into gap between flange and opening in fuel tank.
• The suction-jet pump should click into place.
– Check that suction-jet pump has engaged properly.
– Fit supply line -1- to suction-jet pump connection so that it en‐
gages audibly.
– On vehicles with auxiliary heater, fit suction pipe -2- going to
auxiliary heater so that it engages audibly.

• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.
Note
-Arrow- points in direction of travel.
– Tighten locking ring.
– On vehicles with auxiliary heater, install fuel line -2- leading to
metering pump for auxiliary heater.
unit.
– On vehicles with 4-cylinder TFSI engine the fuel pump should
be adapted after renewing the fuel delivery unit ⇒ page 56 .
Tightening torque
Component Nm
Locking ring for fuel delivery unit 145
3.11 Adapting fuel pump after renewing fuel

delivery unit - vehicles with 4-cylinder
TFSI engine

♦ Vehicle diagnostic, testing and information system - VAS

5051B-
Note
If the fuel pump is renewed on vehicles with 4-cylinder TFSI en‐

gine, the fuel pump should be adapted to the engine control unit
in order to check repair work.
Procedure
• Vehicle diagnostic, testing and information system - VAS
5051B- connected.
• No faults stored in fault memory.
• Engine running at idling speed.
Display on -VAS 5051B- :
– From menu -1-, select “Self diagnosis” system and press →
key to activate function.

– From menu -1-, select vehicle system “01 - Engine electronics”
and press → key to activate function.

– From menu -1-, select function “006 - Basic setting” and press
→ key to activate function.

– Press keys 1 0 3 on keypad -1- to select “Display group 103”
and confirm entry by pressing key Q .
– Activate basic setting by touching Activate key -A-.

– Check information shown in display zone -4-.
Indicated on display: “ADP runs”. When the fuel pump has been
successfully adapted, the display will show “ADP OK”.
Note
If display shows “ADP n.OK”: check fault memory.
– End function “006 - Basic setting” by pressing ← key.

– Select diagnostic function “022 - End output”.
– Switch off ignition and unplug diagnostic connector.


Procedure
Saloon:
Avant:
72 .
Both types:

er stop per stop
Fuel gauge sender - G- 300 … 310 Ω 53.5 … 59 Ω
Note
♦ If the resistance is 0Protected

Ω, there is a short
by copyright. circuit.
Copying If the
for private resistance
or commercial purposes, in part or in whole, is not
is ∞ Ω, there is an open circuit
permitted unlessin the wiring.
bottom position.

er stop per stop

sender - G-
Removing
– Use screwdriver to release retaining tabs -arrows- and lift out
fuel gauge sender - G- .

Caution


unplug connectors.
Installing
– Plug in electrical connectors -1- and -2- and check that they
have engaged properly.
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press downwards until it clicks into place.
– Install fuel delivery unit ⇒ page 55 , observing the instructions
4 Fuel tank on vehicles with four-wheel

drive - vehicles up to 10.2004
Note
The illustration shows a fuel system with fuel return line.
1 - Bracket for exhaust system

2 - Support bracket
❑ To engine
❑ Do not kink
connect
4 - Breather line
housing (front right) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Do not kink permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
connect
❑ From engine
6 - 2 Nm
7 - Heat shield
8 - 23 Nm
9 - Overflow hose
10 - Rubber cup
11 - Tensioning ring
12 - Seal
13 - Filler cap

15 - Breather line
16 - Breather line
17 - Fuel tank
18 - Securing strap
19 - Fastener
20 - 23 Nm
21 - Heat shield
❑ For fuel tank
22 - 2 Nm
23 - 23 Nm

– Hook earth connection contact -1- into mounting hole on fuel
tank -4-.
Caution


♦ Key - T10202-
4. Fuel tank on vehicles with four-wheel drive - vehicles up to 10.2004 63

Procedure
Caution

Rep. gr. 27 .
-arrow 2-.

battery.
Caution

part on the body.
- VAS 5190- .


neck.
Note

– Drain fuel tank as far as possible via fuel filler neck.

– Remove rear seat bench ⇒ Rep. gr. 72 .

– Unscrew cover for flange (right-side) -arrows-.

WARNING

– Detach fuel line -1- from flange.

-2- leading to metering pump for auxiliary heater (press
Protected re‐ Copying for private or commercial purposes, in part or in whole, is not
by copyright.
lease tab). permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

- 3217- or key - T10202- .
– Remove flange with seal from fuel tank opening.

– Unplug electrical connector -arrow- on inside of flange.
– Insert extraction hose to marking -x- = 800 mm through right

opening in fuel tank and into left fuel chamber.
– Draw off fuel in left chamber of fuel tank.
– Re-install flange (right side) ⇒ page 91 ; observe notes on
procedure for connecting battery.

attached components

Removing
dure ⇒ page 63
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Saloon:
Avant: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove left-side
with respect to thesection
correctnessof
of backrest
information in(1/3 section)
this document. ⇒ Rep.
Copyright gr.AG.
by AUDI
72 .

Both types:
– Unbolt cover -arrows-.
– Disconnect breather line -1- by pressing release tab.


– Detach cover for flange (left and right side) -arrows-.
– Unplug electrical connector -arrow- at flange (right-side).

– Unplug electrical connector -arrow- at flange (left-side).
Note


– Disconnect breather lines -2- and -3- from fuel filler neck.
– Unscrew bolt -1- for fuel filler
unlessneck.
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove propshaft ⇒ Rear final drive 01R; Rep. gr. 39 .
WARNING

– Detach heat shields -1- and -2-.

– Detach handbrake cables from retainers marked by -arrows-.
WARNING

tion (press release tab).

All vehicles:
WARNING

1383 A- , simultaneously guiding fuel tank down by hand.

Installing
Note
– Check that fuel lines and breather lines are clipped onto fuel
tank.
• The contact tab -1- must be hooked onto the fuel tank -4-.
– Position fuel tank with securing straps and support bracket on

underbody using engine and gearbox jack - V.A.G 1383 A- .
– Tighten bolts for securing straps and support bracket
-1 ... 10-.
Caution


– Install propshaft ⇒ Rear final drive 01R; Rep. gr. 39 .
Tightening torques
Component Nm
Securing straps and support bracket for fuel 23
tank to body
4.4 Exploded view - fuel delivery unit and fuel gauge senders
Part 1 (right chamber)


❑ Clipped onto baffle
housing in fuel tank
values ⇒ page 86
⇒ page 88
❑ Different versions; for
correct version refer to
⇒ Parts catalogue
❑ Can only be renewed to‐
gether with flange
(electrical test)
⇒ page 74 with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 81
ling
❑ For fuel gauge sender -
G-
❑ For fuel system pressur‐
isation pump - G6-
4 - Flange
❑ For fuel delivery unit
❑ Cannot be renewed
separately
❑ Installation position
⇒ page 85
5 - Seal
❑ Renew
❑ Install dry
6 - Locking ring
7 - Fuel line
❑ To fuel filter
❑ Do not kink
8 - Connecting piece
❑ Different versions; for correct version refer to ⇒ Parts catalogue
❑ Clipped into baffle housing with retaining hooks
❑ To remove, press towards the right to release retaining hooks and lift out
❑ To suction-jet pump in baffle housing


❑ From flange (left-side)
❑ From suction-jet pump (left-side)
12 - Baffle housing
❑ With suction-jet pump
Part 2 (left chamber)
1 - Baffle housing
❑ With suction-jet pump
2 - Connecting piece
⇒ byParts
Protected catalogue
copyright. Copying for private or commercial purposes, in part or in whole, is not
❑with Clipped into
respect to the baffleofhous‐
correctness information in this document. Copyright by AUDI AG.
ing with retaining hooks
❑ To remove, press to‐
wards the right to re‐
lease retaining hooks
and lift out
pump
❑ To suction-jet pump in
baffle housing
pump
❑ From flange (left-side)
5 - Fuel line
❑ From engine or fuel filter
connect
❑ Do not kink
6 - Seal
❑ Renew
❑ Install dry
7 - Locking ring
❑ Depending on version,
remove and install using
key - T10202- or union nut tool - 3217-
❑ For fuel gauge sender 2 - G169-
9 - Flange
❑ Only available together with ⇒ Item 10 (page 73) .
❑ Installation position ⇒ page 96
10 - Fuel gauge sender 2 - G169-
❑ Only available together with ⇒ Item 9 (page 73) .

❑ Checking resistance values ⇒ page 91

❑ With lines
❑ Different versions; for correct version refer to ⇒ Parts catalogue
❑ Secured on flange
❑ Function ⇒ page 96
12 - Fuel supply line permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ From suction-jet pump (left-side)

equipment required

cable - V.A.G 1348/3-2-

Test conditions
• Fuel pump relay - J17- -arrow- OK (located at plug-in position
No. 1 in nine-way relay carrier behind storage compartment
on driver's side).
• Fuel filter OK.
Test sequence
from the top).
Note

– Unplug electrical connector -arrow- at flange (right side of ve‐

hicle).

– Connect hand-held multimeter - V.A.G 1526C- between con‐

tacts -1- and -4- to measure voltage.
If reading matches specification although no noise can be heard

from pump:
delivery unit.



cable - V.A.G 1348/3-2-

Test conditions
• Fuel filter OK.
Test sequence
from the top).

– Detach cover for flange (left-side) -arrows-.
WARNING


– Disconnect fuel line -arrow- from flange (left side of vehicle)

by pressing release tab.
– Fit adapter -V.A.G 1318/17-1- onto disconnected fuel line and

hold adapter hose in measuring container.

Note

– Install rear seat bench ⇒ Rep. gr. 72 .

cable - V.A.G 1348/3-2-

Test conditions
• Fuel filter OK.
Test sequence
from the top).
WARNING

– Disconnect fuel return hose from hose connection on fuel rail.


Note

Note


cable - V.A.G 1348/3-2-

Test conditions
• Fuel filter OK.
Test sequence Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Open fuse box cover on left-hand side of instrumentwith
panel.
respect to the correctness of information in this document. Copyright by AUDI AG.
from the top).

– Remove cover -1- on right side of engine compartment.
WARNING




Note

approx. 2 volts lessby than
Protected battery
copyright. Copyingvoltage.
for private or commercial purposes, in part or in whole, is not
Note

unit
♦ Key - T10202-

♦ Fuel pump spanner - 3307-
Removing
⇒ page 63
Caution

Rep. gr. 27 .

-arrow 2-.
– With ignition switched off, disconnect earth strap -arrow-

Protected at Copying for private or commercial purposes, in part or in whole, is not
by copyright.
battery. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability



hicle).
WARNING

– Detach fuel line -1- from flange (press release tab).

lease tab).
WARNING

- 3217- or key - T10202- .
– Detach flange with seal from fuel tank opening.


Note
– Insert fuel pump spanner - 3307- through fuel tank opening

and apply at fuel delivery unit.
– Release fuel delivery unit by turning to stop (approx 15°) in

anti-clockwise direction (bayonet connection) using fuel pump
spanner - 3307- .
• Notch -1- will then be aligned with marking -2-.
Note
Keep in mind that the fuel delivery unit still contains fuel.
Installing
Note
Renew seal.
– Fit fuel delivery unit into baffle housing (in tank) so that notch
-1- on fuel delivery unit is aligned with marking -2- on baffle
housing.
• The fuelbydelivery
Protected unit should
copyright. Copying for private move down
or commercial noticeably.


– Secure fuel delivery unit by turning to stop (approx 15°) in

clockwise direction (bayonet connection) using fuel pump
spanner - 3307- .
– Attach electrical connector -arrow- to inside of flange.

– Move flange to installation position.
tank.
Note


unit.
Tightening torque
Component Nm


Test sequence


hicle).
er stop per stop
Note

♦ In order to test the maximum and minimum resistance values
for “tank full” and “tank empty”, remove fuel gauge sender - G-
⇒ page 88 and swivel the float all the way to its top or bottom
position.

er stop per stop


er stop per stop
Note
♦ If the resistance isProtected

0 Ω, there is a short
by copyright. circuit.
Copying Iforthe
for private resistance
commercial purposes, in part or in whole, is not
is ∞ Ω, there is an open
permittedcircuit in the wiring.
♦ In order to test the maximum and minimum resistance values
for “tank full” and “tank empty”, remove fuel gauge sender - G-
⇒ page 88 and swivel the float all the way to its top or bottom
position.

er stop per stop
Fuel gauge sender - G- 295 … 305 Ω 52.7 … 57.9 Ω

sender - G-
♦ Key - T10202-
Removing
the flange. Drain the tank if necessary. Procedure ⇒ page 63

Caution

Rep. gr. 27 .

-arrow 2-.

battery.


hicle).
WARNING


– Detach fuel line -1- from flange (press release tab).

lease tab).
WARNING
The fuel tank must not be more than 1/4 full when opening the
flange. Otherwise a large amount of fuel will escape.

- 3217- or key - T10202- .

– Press retaining tab and at the same time pull fuel gauge send‐
er - G- out of baffle housing guide -arrows-.
Note
The baffle housing is shown without fuel tank for illustration pur‐
poses.

Installing
Note
Renew seal.
– Insert fuel gauge sender - G- into guide on outer section of

baffle housing and press down until it clicks into place
-arrow-.

tank.
Note

– Observe instructions for connecting battery ⇒ Rep. gr. 27 .
Tightening torque
Component Nm
4.12 Checking fuel gauge sender 2 - G169-


Test sequence
– Unplug electrical connector -arrow- at flange (left side of ve‐

hicle).

er stop per stop
Fuel gauge sender 2 - G169- approx. 65 Ω approx. 280 Ω
Note

♦ In order to test the maximum and minimum values for “tank
full” and “tank empty”, remove the fuel gauge sender 2 - G169-
⇒ page 93 and move the float all the way to its top or bottom
position. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The following values are obtained with the fuelwith

gauge
respectsender 2
to the correctness of information in this document. Copyright by AUDI AG.
- G169- removed, due to the greater travel of the float arm:

er stop per stop
Fuel gauge sender 2 - G169- approx. 56 Ω approx. 287 Ω

er stop per stop
Fuel gauge sender 2 - G169- 275 … 296 Ω 47 … 65 Ω
Note

position.
♦ The following values are obtained with the fuel gauge sender 2

er stop per stop
Fuel gauge sender 2 - G169- 295 … 305 Ω 45.5 … 48.1 Ω

sender 2 - G169-

♦ Key - T10202-
Removing
fuel gauge sender 2 - G169- . Drain the tank if necessary.
Procedure ⇒ page 63
Caution

Rep. gr. 27 .

-arrow 2-.

battery.



hicle).
WARNING


WARNING
fuel gauge sender 2 - G169- . Otherwise a large amount of fuel
will escape.
– Depending on version, unscrew locking ring using key -

T10202- or union nut tool - 3217- (left side of vehicle).
– Carefully pull flange with fuel gauge sender 2 - G169- and seal
just slightly out of opening in fuel tank.
– First pull fuel line -1- out of
permitted fuelauthorised
unless tank. by AUDI AG. AUDI AG does not guarantee or accept any liability
– Swivel flange -2- with fuel gauge sender 2 - G169- -item 3- and
suction-jet pump -4- out of fuel tank opening.
Note
When removing, make sure you do not bend float arm of fuel
gauge sender 2 - G169- .
– Unclip suction-jet pump from flange with fuel gauge sender 2

- G169- .

– Press release tabs -arrows- and disconnect fuel hose at Y-

connector.
– Remove flange with fuel gauge sender 2 - G169- .
Installing
Note
♦ Renew seal.
♦ When installing, make sure you do not bend float arm of fuel
♦ Ensure that fuel hose is securely connected.

tank.
Note

Tightening torque
Component Nm
Locking ring for flange of fuel gauge sender 2 - 145
G169-
4.14 Suction-jet pump

1 - Suction-jet pump (left-side)

♦ On vehicles with four-wheel
drive the fuel tank is divided
into a left and a right cham‐
ber.
♦ A so-called suction-jet
pump -1- is used for deliv‐
ering the fuel from the left
fuel tank chamber to the
baffle housing of the fuel
delivery unit -8- on the right.
♦ A second suction-jet pump
-7- is located in the right fuel
tank chamber and serves to
improve the fuel delivery in
the right fuel tank chamber
to the baffle housing of the
fuel delivery unit.
♦ The suction-jet pumps op‐
erate according to the prin‐
ciple of fluid entrainment: a
stream of fuel from the fuel
return line -3- is pressed
through a nozzle in the suc‐
tion-jet pumps -1- and -7-,
and is thus accelerated.
The accelerated stream of
fuel draws off the surround‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ing fuel and delivers it to the permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
baffle housing of the fuel

delivery unit. The right suc‐

tion-jet pump -7- delivers
the fuel directly into the baf‐
fle housing, the left suction-
jet pump -1- delivers the
fuel via a separate pipe -4-.
♦ The fuel is distributed from
the return line to the two
suction-jet pumps via the Y-connector -2-. At the same time the connecting piece -6- limits the pressure in
the pipes leading to the suction-jet pumps to approx. 1 bar. Excess fuel is delivered directly to the baffle
housing via a pipe.
Note
4.15 Removing and installing suction-jet

pump in left fuel tank chamber

♦ Key - T10202-
♦ Fuel pump spanner - 3307-
Removing
Note
This section describes how to remove the suction-jetProtected

pump byincopyright.
the Copying for private or commercial purposes, in part or in whole, is not
left fuel tank chamber. The suction-jet pump in the right fuel tank
chamber is part of the baffle housing and cannot be renewed

separately.

the suction-jet pump for the left fuel tank chamber. Drain the
tank if necessary. Procedure ⇒ page 63
Caution

Rep. gr. 27 .

-arrow 2-.


battery.


hicle).
WARNING

– Disconnect fuel line -1- from flange (right side of vehicle) by

pressing release tab.
lease tab).

WARNING

- 3217- or key - T10202- .
– Detach flange with seal from fuel tank opening.

Note

– Release fuel delivery unit by turning to stop (approx 15°) in

anti-clockwise direction (bayonet connection) using fuel pump
spanner - 3307- .
Note
Keep in mind that the fuel delivery unit still contains fuel.


hicle).
WARNING


– Depending onwithversion, unscrew
respect to the locking
correctness ringin using
of information key -Copyright by AUDI AG.
this document.

– Carefully pull flange with fuel gauge sender 2 - G169- and seal
just slightly out of opening in fuel tank.
– First pull fuel line -1- out of fuel tank.
– Swivel flange -2- with fuel gauge sender 2 - G169- -item 3- and
suction-jet pump -4- out of fuel tank opening.
Note

- G169- .
– Press release tabs -arrows- and disconnect fuel hose at Y-

connector.
– Reach into fuel tank opening on right side of vehicle and pull
fuel supply line -4- out of baffle housing.
– Press connecting piece -1- to the right and unclip it from baffle
housing.
– Disconnect supply line -3- for suction-jet pump from connect‐
ing piece -1-.
Note
Fuel line -2- remains connected.
– Reach into fuel tank opening on left side of vehicle and pull out
suction-jet pump, with pipes pointing towards the left.
Installing
Note
♦ Renew seals.
– Push suction-jet pump (with pipes attached) into fuel tank

opening on left side of vehicle.

suction-jet pump with pipes into the installation position.
– Push supply line -3- for suction-jet pump onto connecting
piece -1- so that the hose connectors engage.
– Clip connecting piece onto baffle housing.
– Fit fuel supply line -4- into corresponding hole in baffle hous‐
ing.
– Clip suction-jet pump -4- onto flange -2- of fuel gauge sender
2 - G169- and fit fuel line to Y-connector -1-.
Note
When installing, make sure you do not bend float arm of fuel

– Move flange with fuel gauge sender 2 - G169- into installation
position.
tank.
Note

Note
– Fit fuel delivery unit into baffle housing (in tank) so that notch
-1- on fuel delivery unit is aligned with marking -2- on baffle
housing.
• The fuel delivery unit should move down noticeably.

– Secure fuel delivery unit by turning to stop (approx 15°) in

clockwise direction (bayonet connection) using fuel pump
spanner - 3307- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not



tank.
Note

Tightening torque
Component Nm
Locking ring for fuel delivery unit or flange of fuel 145
gauge sender 2 - G169-

5 Fuel tank on vehicles with four-wheel

drive - vehicles from 11.2004 on‐
wards
Note
The illustration shows a fuel system without fuel return line.
1 - Bracket for exhaust system

2 - Support bracket
3 - Fuel line
❑ To engine
❑ Do not kink
connect
4 - Breather line
❑ Do not kink
connect
5 - 2 Nm
6 - Heat shield
7 - 23 Nm
8 - Overflow hose Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Rubber cup with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Tensioning ring
11 - Seal
12 - Filler cap

14 - Breather line
15 - Breather line
16 - Fuel tank
17 - Securing strap
18 - Fastener
19 - 23 Nm
20 - Heat shield Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For fuel tank with respect to the correctness of information in this document. Copyright by AUDI AG.
21 - 2 Nm
22 - 23 Nm

– First engage contact tab -2- of earth connection in mounting
hole on fuel tank -5- and then press in spacer bush -1- if fitted.
Caution


♦ Key - T10202-
5. Fuel tank on vehicles with four-wheel drive - vehicles from 11.2004 onwards 107
Procedure
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Audi RS 4:
– Lift luggage compartment floor and securepermitted
in position.
battery.

All vehicles:
Caution

part on the body.
- VAS 5190- .
Protected bytance ofCopying
copyright. -a- = for
1,865
privatemm from end
or commercial of hose.
neck.
Note

– Drain fuel tank as far as possible via fuel filler neck.


Audi RS 4:
– Pull wiring with connector -arrow- out of opening for flange and
move to one side.
All vehicles:
hicle).
– Mark fuel return line -1- and fuel supply line -2-.
WARNING


tab).

- 3217- or key - T10202- .

– Insert extraction hose to marking -x- = 800 mm through right

opening in fuel tank and into left fuel chamber.
– Draw off fuel in left chamber of fuel tank.
– Re-install flange (right-side) ⇒ page 147 ; observe notes on
procedure for connecting battery ⇒ Rep. gr. 27 .

attached components

Removing
dure ⇒ page 107
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Audi RS 4:
battery.
All vehicles:
Saloon:
Avant:
72 .
Both types:
– Unbolt cover -arrows-.
– Disconnect breather line -1- by pressing release tab.



– Detach cover for flange (left and right side) -arrows-.
Audi RS 4:
move to one side. with respect to the correctness of information in this document. Copyright by AUDI AG.
All vehicles:
hicle).

hicle).
Note


– Disconnect breather lines -2- and -3- from fuel filler neck.
– Remove propshaft ⇒ Rear final drive 01R; Rep. gr. 39 .
WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


– Detach heat shields -1- and -2-.
– Detach handbrake cables from retainers marked by -arrows-.
WARNING



fuel tank by pressing
Protectedrelease tabs.
– On vehicles with auxiliary heater,
with respect to also ofdisconnect
the correctness fuel
information in this line Copyright by AUDI AG.
document.
All vehicles:
WARNING

1383 A- , simultaneously guiding fuel tank down by hand.
Installing
Note
– Check that fuel lines and breather lines are clipped onto fuel
tank.

• Contact tab -2- must be attached on fuel tank -5- and secured
with spacer bush -1-, if fitted.
– Position fuel tank with securing straps and support bracket on

underbody using engine and gearbox jack - V.A.G 1383 A- .
– Tighten bolts for securing straps and support bracket permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
-1 ... 10-. with respect to the correctness of information in this document. Copyright by AUDI AG.
Caution


– Install propshaft ⇒ Rear final drive 01R; Rep. gr. 39 .
Tightening torques
Component Nm
tank to body
5.4 Exploded view - fuel delivery unit and fuel gauge senders


values ⇒ page 150
⇒ page 152
(electrical test)
⇒ page 119
⇒ Parts catalogue
⇒ page 144
ling
3 - Seal
❑ Renew
❑ Install dry
4 - Locking ring
❑ Depending on version,
remove and install using
key - T10202- or union
nut tool - 3217-
5 - Fuel supply line Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To fuel filter permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Do not kink
❑ To disconnect from
flange, press release tab on connection piece
❑ Do not kink
❑ To disconnect from flange, press release tab on connection piece
7 - Fuel line to metering pump
❑ For auxiliary heater
❑ From fuel pump to suction-jet pump
❑ For fuel gauge sender 2 - G169-
11 - Locking ring
12 - Seal
❑ Renew
❑ Install dry
❑ Checking suction-jet pump ⇒ page 158
14 - Fuel gauge sender 2 - G169-
❑ Checking resistance values ⇒ page 152
❑ From suction-jet pump to fuel delivery unit
❑ Clipped onto fuel delivery unit


equipment required

cable - V.A.G 1348/3-3-
Test conditions
• Vehicles with MPI engine: Fuel pump relay - J17- -arrow- OK

(located at plug-in position No. 1 in nine-way relay carrier be‐
hind storage compartment on driver's side).
• Vehicles with FSI engine: fuel pump control unit - J538- must
be OK; checking ⇒ page 121 .
• Fuel filter OK.
Test sequence
Audi RS 4: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull wiring with connector -arrow- out of opening for flange and to the correctness of information in this document. Copyright by AUDI AG.
with respect
move to one side.

All vehicles:
hicle).

– Tape off 2nd connector contact of the adapter cable -
V.A.G 1348/3-3- with insulating tape -arrow- to prevent short
circuits.
Note

delivery unit.
– Install fuel delivery unit ⇒ page 147 by
Protected . copyright. Copying for private or commercial purposes, in part or in whole, is not
5.6 Checking fuel pump control unit - J538- - vehicles with 4-cylinder TFSI en‐
gine

equipment required

♦ Adapter cable - V.A.G 1598/39-
♦ Test box - V.A.G 1598/42-
Test conditions

Checking voltage supply for fuel pump (from fuel pump control
unit - J538- )
– Push back protective sleeve.

– Connect hand-held multimeter - V.A.G 1526C- (voltage test
range) with probes and plug-in adapters from auxiliary meas‐
uring set - V.A.G 1594C- between contacts -1- and -4-, as
shown in illustration. The connector remains in place.
Note

the connector.
– Start engine.
• Specification when starting and at idling speed: approx.
4 ... 5.7 V.
– Check voltage supply and activation of fuel pump control unit
- J538- .
Checking voltage supply for fuel pump control unit - J538-

– Remove fuel
permitted pump
unless control
authorised unit
by AUDI - AUDI
AG. J538-AG ⇒ page
does 125 . or accept any liability
not guarantee
– Unplug electrical connector -arrow- on fuel pump control unit
- J538- .
– Connect multimeter between contacts -3- and -4- of connector

to measure voltage.
– Switch on ignition.
Checking activation of fuel pump control unit - J538-

– Remove protective cap.
– Connect multimeter (voltage test range) with probes and plug-
in adapters from auxiliary measuring set - V.A.G 1594C- be‐
tween contacts -4- and -5-, as shown in illustration. The
electrical connector remains in place.
Note

the connector.
– Start engine.
• Specification when starting and at idling speed: approx. 5.0 V.

– Switch off ignition.
– Connect the test box - V.A.G 1598/42- to wiring harness with
adapter lead -V.A.G 1598/39-1- or adapter lead -V.A.G
1598/39-2- . Do not connect engine control unit. Connect earth
clip of test box to negative terminal of battery ⇒ Rep. gr. 24 .
Caution
To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector -V.A.G 1598/42-
Contact Socket
-5- B 27
– Repair open circuit or short circuit in wiring (refer to current
flow diagram).
If no fault is found:
– Renew fuel pump control unit - J538- .
5.7 Checking fuel pump control unit - J538-

- vehicles with 6-cylinder and 8-cylinder
FSI engine
The procedure for checking the fuel pump control unit - J538- is
carried out in “Guided Fault Finding” with vehicle diagnostic, test‐
ing and information system - VAS 5051B- .
5.8 Removing and installing fuel pump con‐

trol unit - J538-
Removing
• Fuel tank must be empty when lowering it to reduce weight.
Drain the tank if necessary. Procedure ⇒ page 107
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Audi RS 4:
– Lift luggage compartment floor and secure in position.
battery.
All vehicles:
Note


Note
Disregard -item 2-.
– Remove cover -1- from underside of vehicle (rear right).
WARNING
To reduce weight, fuel tank must be empty when lowering it.

– Loosen bolts -1 ... 5-, -9- and -10- by turning not more than 8
turns.
– Unscrew bolts -6-, -7- and -8-.

Audi RS 4:
– Move electrical connector -arrow- for fuel pump control unit -
J538- clear and unplug connector.
All vehicles:
hicle).
WARNING


tab).
– Remove bolts -arrows-.

– Remove fuel pump control unit - J538- .
Installing
– Tighten bolts for securing straps and support bracket
-1 ... 10-.

– Secure fuel filler neck with earth connection using bolt -1-.
Caution

– Secure breather line -3- to fuel filler neck.
Note
Disregard -item 2-.
– Install rear right wheel housing liner ⇒ Rep. gr. 66 .

Tightening torques
Component
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any Nmliability
tank to body
Fuel pump control unit - J538- to underbody 2.5


cable - V.A.G 1348/3-2-

Test conditions
• Fuel filter OK.
Test sequence
from the top).
– Remove rear seat bench ⇒ Rep. gr. 72 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
WARNING


– Disconnect fuel return line -1- from flange (right side of vehicle)
Note
Disregard -item 2-.
– Fit adapter -V.A.G 1318/17-1- onto disconnected fuel line and

hold adapter hose in measuring container.

Note



cles with 4-cylinder TFSI engine
♦ Adapter set - V.A.G 1318/10-12-

cable - V.A.G 1348/3-3-

Test conditions
• Battery voltage at least 12.5 V Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Fuel filter OK. with respect to the correctness of information in this document. Copyright by AUDI AG.

Test sequence


hicle).

circuits.

WARNING

– Disconnect fuel line -arrow- from pipe connection on engine.

rection of flow.

Note


Tightening torque
Component Nm

cable - V.A.G 1348/3-2-

Test conditions
• Fuel filter OK.


Test sequence
from the top).
WARNING



Note

Note

♦ Adapter Protected
set - V.A.G 1318/10-12-
♦ Remote control - V.A.G
with respect 1348/3A-
to the correctness for V.A.G
of information 1348
in this withCopyright
document. adapter by AUDI AG.
cable - V.A.G 1348/3-3-

Test conditions
• Fuel filter OK.
• Fuel pump control unit - J538- OK; checking in “Guided Fault

Finding” using vehicle diagnostic, testing and information sys‐
tem - VAS 5051B- .

Test sequence

hicle).

circuits.

WARNING

– Disconnect fuel line -arrow-.

rection of flow.

Note

causes:
Tightening torque
Component Nm



cable - V.A.G 1348/3-2-

Test conditions
• Fuel filter OK.
• Ignition switched off.by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
Test sequence with respect to the correctness of information in this document. Copyright by AUDI AG.

from the top).

WARNING



Note

Note

cles with
permitted 8-cylinder
unless authorised by AUDI FSI engine
AG. AUDI AG does not guarantee or accept any liability
♦ Adapter set - V.A.G 1318/10-12-


cable - V.A.G 1348/3-2-

Test conditions
• Fuel filter OK.
• Fuel pump control unit - J538- OK; checking in “Guided Fault

Finding” using vehicle diagnostic, testing and information sys‐
tem - VAS 5051B- .
Test sequence
move to one side.

hicle).

–Protected
Tapeby off 2nd Copying
copyright. connector contact
for private of the
or commercial adapter
purposes, in partcable - V.A.G
or in whole, is not
– Slide cover to right -arrow 1- and lift it off -arrow 2-.

– Connect crocodile clip to positive terminal (+).

WARNING

– Disconnect fuel supply line -arrow- at fuel rail.

rection of flow.

Note


causes:
Tightening torque
Component Nm

unit
♦ Key - T10202-
Removing
⇒ page 107

Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Audi RS 4:
battery.
All vehicles:

Audi RS 4:
All vehicles:
hicle).
WARNING

place a Protected
clean cloth around the connection. Then carefully loos‐
en the connection
permitted unlessto relieve by the
AUDI pressure.
authorised AG. AUDI AG does not guarantee or accept any liability

tab).
WARNING

- 3217- or key - T10202- .
– Take flange and seal out of opening in fuel tank and move
flange clear, leaving pipes connected.

– Disconnect supply line -1- for suction-jet pump by pressing

release tab.
– Disengage fuel supply line -2-.
Note
Installing
Note
♦ Renew seal.
Take care not to bend the fuel gauge sender - G- when fitting
♦ by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
the fuel delivery unit.
– Insert fuel delivery unit into fuel tank, with flange set aside.
– Engage fuel supply line -2-.
– Fit supply line -1- leading to suction-jet pump so that it engages
audibly.
Make sure fuel hoses are properly routed.

♦ The fuel supply line -1- must be routed between the guide tube
-4- and the connecting piece -2- for fuel return line. Also make
sure that it is routed around outside of guide tube -3-.
– Insert guide tubes -3- and -4- on flange into corresponding
holes -arrows- in fuel delivery unit.
Note
The fuel delivery unit is shown without the fuel tank for illustration
purposes.

tank.

unit.
– On vehicles with 4-cylinder TFSI engine the fuel pump should
be adapted after renewing the fuel delivery unit ⇒ page 148 .
Tightening torque
Component Nm
5.16 Adapting fuel pump after renewing fuel

delivery unit - vehicles with 4-cylinder
TFSI engine
♦ Vehicle diagnostic, testing and information system - VAS
5051B-
Note
If the fuel pump is renewed on vehicles with 4-cylinder TFSI en‐

gine, the fuel pump should be adapted to the engine control unit
in order to check repair work.
Procedure
5051B- connected.
• Engine running at idling speed.





– Press keys 1 0 3 on keypad -1- to select “Display group 103”

– Check information shown in display zone -4-.
Indicated on display: “ADP runs”. When the fuel pump has been
successfully adapted, the display will show “ADP OK”.
Note
If display shows “ADP n.OK”: check fault memory.


Test sequence

Audi RS 4:
move to one side.
All vehicles:
hicle).

er stop per stop
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

bottom position.

er stop per stop
Fuel gauge sender - G- 295 … 305 Ω 52.7 … 57.9 Ω

sender - G-
Removing
– Use screwdriver to release retaining tabs -arrows- and lift out
fuel gauge sender - G- .
Caution


unplug connectors.
Installing
– Plug in electrical connectors -1- and -2- and check that they
have engaged properly.
– Insert fuel gauge sender - G- into guides on fuel delivery
permitted unlessunit
and press downwards until it clicks into place. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install fuel delivery unit ⇒ page 147 , observing the instructions
5.19 Checking fuel gauge sender 2 - G169-


Test sequence

hicle).

er stop per stop
Fuel gauge sender 2 - G169- 275 … 296 Ω 47 … 65 Ω
Note

position. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The following values are obtained with
with respect thecorrectness
to the fuel gauge sender
of information 2 document. Copyright by AUDI AG.
in this

er stop per stop
Fuel gauge sender 2 - G169- 295 … 305 Ω 45.5 … 48.1 Ω

sender 2 - G169-
♦ Key - T10202-
Removing
fuel gauge sender 2 - G169- . Drain the tank if necessary.
Procedure ⇒ page 107

Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Audi RS 4:
battery.
All vehicles:

– Detach cover
permitted forauthorised
unless flange by (left-side) -arrows-.
AUDI AG. AUDI AG does not guarantee or accept any liability

hicle).
WARNING
fuel gauge sender 2 - G169- . Otherwise a large amount of fuel
will escape.

– Carefully pull flange -1-permitted
with fuel gauge sender 2 - G169- and
suction-jet pump -2- just slightly out of opening in fuel tank.

Note

- G169- .
– Remove flange with fuel gauge sender 2 - G169- .
Installing
Note
♦ Renew seal.
– Clip suction-jet pump onto flange, so that you hear it click into
place.
– Carefully insert fuel gauge sender 2 - G169- into opening in
fuel tank.


tank.
Note

Tightening torque
Component Nm
Locking ring for flange of fuel gauge sender 2 - 145
G169-
5.21 Suction-jet pump

On vehicles with four-wheel drive the fuel tank is divided into a
left and a right chamber. A so-called suction-jet pump -1- is used
for delivering the fuel from the left fuel tank chamber -3- to the
baffle housing of the fuel delivery unit -2- on the right.
Suction-jet pump: operation
The suction-jet pump operates according to the principle of fluid
entrainment: the stream of fuel from the electric fuel pump is
passed through a nozzle in the suction-jet pump, and is thus ac‐
celerated. The accelerated stream of fuel draws off the surround‐
ing fuel and delivers it to the baffle housing of the fuel delivery
unit.
Faults caused by defective suction-jet pump
Caution
If the suction-jet pump is defective, the engine can stop due to

fuel starvation when the tank is still 1/4 full.
If suction-jet pump is not working, up to 20 litres of fuel (up to

about 1/4 of tank capacity) may remain in the left chamber of the
tank, where it cannot enter the fuel delivery unit.
If the engine stops due to fuel starvation with the tank up to about
1/ full, proceed as follows:
4
– Check fuel pump ⇒ page 119 .
If fuel pump is OK, but no fuel is delivered:
– Put another 5 litres (approx.) of fuel into tank.
– Start engine.
If engine now starts:
– Renew suction-jet pump ⇒ page 158 .
5.22 Removing and installing suction-jet

pump
♦ Key - T10202-
Removing

the suction-jet pump. Drain the tank if necessary. Procedure
⇒ page 107
Caution

Rep. gr. 27 .

-arrow 2-.

battery.
Audi RS 4:
battery.
All vehicles:

Audi RS 4:
All vehicles:
hicle).
WARNING


tab).
WARNING

- 3217- or key - T10202- .
– Take flange and seal out of opening in fuel tank and move
flange clear, leaving pipes connected.

– Disconnect supply line -1- for suction-jet pump by pressing

release tab.
– Disengage fuel supply line -2-.

hicle).

– Carefully pull flange -1- with fuel gauge sender 2 - G169- and
suction-jet pump -2- towards left out of opening in fuel tank.
Note
Installing
Installation is carried out in the reverse order; note by the following:
permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
Note
♦ Renew seal.
– Push suction-jet pump (with pipes attached) into fuel tank

opening on left side of vehicle.
suction-jet pump with pipes into the installation position.
– Engage fuel supply line -2-.
– Fit supply line -1- leading to suction-jet pump so that it engages
audibly.
Make sure fuel hoses are properly routed.

♦ The fuel supply line -1- must be routed between the guide tube
-4- and the connecting piece -2- for fuel return line. Also make
sure that it is routed around outside of guide tube -3-.
– Insert guide tubes -3- and -4- on flange into corresponding
holes -arrows- in fuel delivery unit.
Note
The fuel delivery unit is shown without the fuel tank for illustration
purposes.


tank.
– Tighten locking ring (right-side).

tank.
Note
– Tighten locking ring (left-side).
– Secure cover for flange (left and right side) -arrows-.

Tightening torque
Component Nm
Locking ring for fuel delivery unit or flange of fuel 145
gauge sender 2 - G169-

6 Servicing fuel filter
6.1 Removing and installing fuel filter - fuel

system with fuel return line
♦ Reservoir
Removing
– Remove cover panel at right of fuel tank -arrows-.
– Place drip tray below fuel filter.
WARNING

– Disconnect fuel lines -1- and -3- by pressing release tabs.

– Remove bolt -2-.
– Remove fuel filter.
Installing
Installation position:
• Flow direction is marked with arrows on filter housing.
• Arrows -1- and -2- must be face each other.
6. Servicing fuel filter 165

Distance between fuel return line at fuel filter and fuel tank:
• Front-wheel drive: -a- = 6 … 10 mm.
• Four-wheel drive: -a- = 3 … 7 mm.
Tightening torque
Component Nm
Retaining clamp for fuel filter 1.2
6.2 Removing and installing fuel filter - fuel

system without fuel return line
♦ Reservoir
Removing
– Remove cover -1- on rear right side of fuel tank.
WARNING

– Disconnect fuel lines -1-, -2- and -4- by pressing release tabs.
Note
Illustration shows front-wheel drive vehicle.

Installing
Installation position:
• Flow direction is marked with arrows on filter housing.
• Connection “IN” for fuel supply line -3- must be level with bol‐
ted connection on filter bracket -2- on vehicles with front-wheel
drive.
Distance between fuel return line at fuel filter and fuel tank:
• Front-wheel drive: -a- = 6 … 10 mm.
• Four-wheel drive: -a- = 3 … 7 mm.
Tightening torque
Component Nm
6.3 Removing and installing fuel filter - ve‐

hicles with 1.8 ltr. turbo engine with
front-wheel drive (all versions) or with
four-wheel drive up to 10.2004
♦ Reservoir Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing

– Remove cover panel at right of fuel tank -arrows-.
WARNING

– Disconnect the following fuel lines on the fuel filter:

1- Fuel supply line from fuel tank
2- Fuel return line going to fuel tank
3- Breather line
4- Supply line going to engine
Note
Illustration shows vehicle with four-wheel drive.
6. Servicing fuel filter 167

Installing
• Direction of flow is indicated by arrows -1-.
• “IN” connection must be level with bolted connection on filter
bracket -arrows-.
– Fit fuel lines according to markings.

1- Fuel supply line from fuel tank “VL”
2- Return line “RL”
3- Breather line “E”
4- Supply line going to engine “MOTOR”
Note
Illustration shows vehicle with four-wheel drive.
Tightening torque
Component Nm

7 Bleeding fuel system
7.1 Vehicles with 1.8 ltr. turbo engine

In order to prevent damage to the catalytic converter, the fuel
system without return line must be bled after working on the fuel
lines or the fuel filter. Do not start the engine until the fuel system
has been bled.
Bleed fuel system ⇒ Rep. gr. 24 .
7. Bleeding fuel system 169

8 Servicing components of activated

charcoal filter system
8.1 Removing and installing activated char‐

coal filter
Removing
– Remove front wheel (right-side).
– Remove front right wheel housing liner ⇒ Rep. gr. 66 .
– Remove cover panel from front right of underbody -arrows-.
– Disconnect breather line leading to fuel tank -arrow- (press

release tab).
– Remove bolts -arrows-.

– Disengage activated charcoal filter solenoid valve 1 - N80-
-item 1- at air duct.
– Remove air duct -2-.

– Remove air cleaner housing -arrows-.
– Detach breather line from activated charcoal filter solenoid

valve 1 - N80- -arrow-.
– Pull pipe from wheel housing out of engine compartment and
move clear to one side.
– Unscrew bolt -arrow- and detach activated charcoal filter at top

mounting.
– Remove activated charcoal filter with breather lines.
Installing
Note
– Attach activated charcoal filter at top mounting.

– Secure activated charcoal filter to wheel housing.
– Install front right wheel housing liner ⇒ Rep. gr. 66 .
Tightening permitted
torque unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Component Nm
Activated charcoal filter to body 1.5
8. Servicing components of activated charcoal filter system 171

9 Servicing accelerator mechanism
9.1 Exploded view - accelerator pedal module
1 - Accelerator pedal module

❑ With accelerator posi‐
tion sender - G79- and
accelerator position
sender 2 - G185-
⇒ page 173
2 - 10 Nm
4 - 10 Nm

9.2 Removing and installing accelerator

pedal module with accelerator position
sender
Removing
– Remove storage compartment on driver's side ⇒ Rep. gr. 68 .
– Unplug electrical connector -2-.
– Remove bolts -1- and -3-.
– Remove accelerator pedal module.
Installing
– Install storage compartment on driver's side ⇒ Rep. gr. 68 .
Vehicles with automatic gearbox:
If accelerator position sender or engine control unit is replaced,
kick down function must be adapted on vehicles with automatic
gearbox ⇒ page 173 .
Tightening torque
Component Nm
Accelerator pedal module to pedal bracket 10
9.3 Adapting kick-down function after re‐

newing accelerator pedal position send‐
er or engine control unit
Note
If accelerator position sender or engine control unit is replaced,

kick down function must be adapted on vehicles with automatic
gearbox.

♦permitted
Vehicle diagnostic,
unless testing
authorised by AUDI andAGinformation
AG. AUDI system
does not guarantee or accept- any
VAS liability
5051B-
Procedure
5051B- connected.
• Engine stopped, ignition switched on
9. Servicing accelerator mechanism 173





– Press keys 6 3 on keypad -1- to select “Display group 063”


– Check display in display zones -3- and -4-.
Display shows: “Operate kickdown”
– Fully depress accelerator pedal beyond kickdown point and
keep it pressed.
Display shows: “Kickdown ADP runs”
– Check the readout in display zones -3- and -4-.
Display shows: “Kickdown ADP O.K.”
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ If the display shows “Kickdown ERROR”: interrogate fault

memory.
♦ “ERROR” is indicated, for example, if the accelerator pedal is
not pressed immediately after requested by the tester or if the
accelerator pedal is released before the adaption process is
finished. Exit function “006 - Basic setting” by pressing ← key
and restart adaption.

9. Servicing accelerator mechanism 175

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Service Department. Technical Information

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Copyright © 2017 Audi AG, Ingolstadt A0059006220

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 – Fuel supply system

1.1 Safety precautions when working on the

The fuel system is pressurised. Before opening the system

Perform the following steps before starting to work on the fuel

Observe notes on procedure for disconnecting the battery ⇒

♦ With ignition switched off, disconnect earth strap from battery.

1.2 Rules for cleanliness

When working on the fuel supply/injection system, paydocument.

1. Notes for working on fuel supply system 1

♦ After removal, place parts on a clean surface and cover them.

2 Rep. gr.20 - Fuel supply system

2 Fuel tank on all front-wheel drive ve‐

2.1 Exploded view - fuel tank with components

The illustration shows a fuel system with fuel return line.

1 - Fuel supply line

Installation position of earth connection

After installation, use an ohmmeter to check the electrical con‐

2.2 Draining fuel tank

4 Rep. gr.20 - Fuel supply system

Observe notes on procedure for disconnecting the battery ⇒

– Push battery cover to the right -arrow 1- and lift it off

– With ignition switched off, disconnect earth strap -arrow- at

Secure earth wire of fuel extractor - VAS 5190- to a bare metal

– Remove filler cap from fuel filler neck.

♦ The procedure when using a fuel extractor without shaft end

– Drain fuel tank via fuel filler neck.

2.3 Removing and installing fuel tank with

♦ Engine and gearbox jack - V.A.G 1383 A-

Observe notes on procedure for disconnecting the battery ⇒

– Push battery cover to the right -arrow 1- and lift it off

6 Rep. gr.20 - Fuel supply system

– With ignition switched off, disconnect earth strap -arrow- at

– Unplug electrical connector -arrow- at flange.

Vehicles with hose connection:

Vehicles with plug-in connector:

Do not remove filler cap.

– Clean area around fuel filler neck.

– Remove rear wheel (right-side).

– Remove trim panel on underbody -arrows-.

8 Rep. gr.20 - Fuel supply system

– Remove underbody covers -1- and -2-.

BEFORE loosening subframe bolts, take steps to ensure that

– Remove rear axle ⇒ Rep. gr. 42 .

– Disengage handbrake cable from front right of fuel tank at

The fuel system is pressurised. Before opening the system

Vehicles with 1.8 ltr. turbo engine:

The fuel system is pressurised. Before opening the system

To reduce weight, fuel tank must be empty upon removal.

– Remove bolts -1 ... 7-.

10 Rep. gr.20 - Fuel supply system

– Check the earth wiring at both ends for traces of oxidation.

– Position fuel tank with securing straps on underbody using

After installation, use an ohmmeter to check the electrical con‐

– Install rear axle ⇒ Rep. gr. 42 .

2.4 Exploded Protected

Illustration shows fuel delivery unit on vehicles with 6-cylinder engine.

1 - Fuel gauge sender - G-

12 Rep. gr.20 - Fuel supply system