Fuel Supply, Generic Scan Tool -1.8l 5v Turbo, Amb Audi A4 B6

General Repair Notes

Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY SYSTEM .

Observe rules for cleanliness. See RULES OF CLEANLINESS .

Safety precautions when working on fuel supply system

The following steps should be taken before beginning work on the fuel supply system

1. Disconnect battery Ground (GND) strap with the ignition switched off.
2. Open fuel tank cap briefly and then close again.

When removing and installing components from full or partially filled fuel tanks, the following must be observed

1. The fuel tank may only be partially filled. How much fuel can remain in the fuel tank may be read in the respective work description. Empty fuel tank if necessary. Procedure for vehicles with Front Wheel Drive (FWD), see «EMPTY FUEL TANK»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__empty-fuel-tank) . For vehicles with All Wheel Drive (AWD), see «EMPTY FUEL TANK»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
2. Already before starting work, switch on exhaust extraction system and place an extraction hose close to the sensor installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h can be used.
3. Prevent fuel from contacting skin! Wear fuel-resistant gloves!

Rules of cleanliness

When working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths only!
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (in tool boxes etc.)
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Fuel supply system - Front Wheel Drive (FWD) - Vehicles up to 06.2003

Note. Secure all hose connections using hose clamps appropriate for the model type. VAG1921 hose clip pliers are recommended for installing spring-type clamps. Always replace seals and gaskets.

Fuel tank with attachments - component overview

Note. The following list refers to (Scheme 208).

1. Fuel supply line from fuel filter To engine Do not bend To disconnect, press release button on connection piece
2. not installed
3. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Do not bend To disconnect, press release button on connection piece Clipped in on fuel tank
4. Electrical harness connector For fuel tank lock switch
5. 23 N.m Serves to secure fuel filler neck and Ground (GND) connection. See item 11 .
6. Overflow hose Engaged in wheelhouse
7. Rubber pan
8. Tensioning ring
9. Seal Replace if damaged
10. Cap
11. Ground (GND) connection For discharging electrostatic charge Installed position / check requirements. See «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__installation-position-of-ground-gnd-connection) . Ensure secure seating of connector and secure wire with securing bolt for fuel filler tube. See item 9 . After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter. Specified value: approx. 0ohm
12. Vent line
13. Vent line from gravity valve to EVAP canister To remove, press release ring on EVAP canister
14. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clipped in on fuel tank
15. Fuel tank Empty if necessary, to remove components. See «EMPTY FUEL TANK»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__empty-fuel-tank) .
16. Heat shield for fuel tank
17. 2 N.m
18. Heat shield for fuel tank
19. 2 N.m
20. Expanding clip
21. Tension strap Note varying lengths
22. 23 N.m

Installation position of Ground (GND) connection

1. Route Ground (GND) connection (Scheme 209)
2. Engage contact -1- of Ground (GND) connection into securing opening on fuel tank -4-.
3. Ensure connector -3- of Ground (GND) connection fits securely at metal ring -2- of fuel filler tube.

Scheme 208

Fuel Pump (FP) and Sender for fuel gauge - component overview

Note. The following list refers to (Scheme 210).

1. Sender for fuel gauge -G
2. Fuel pump Check Fuel Pump (FP) electrically. See «FUEL PUMP (FP), ELECTRICAL TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking fuel delivery. See «DELIVERY QUANTITY OF FUEL PUMP (FP), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking residual pressure. See «SYSTEM PRESSURE AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__system-pressure-and-residual-pressure-checking) . Removing and installing. See «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-removing-and-installing) .
3. Seal replace to install, place into opening of fuel tank dry
4. Fuel return line Mark before removing To disconnect, press release button on connection piece Do not bend Note direction of arrow (fuel supply or return) on connector flange when installing Clipped in on fuel tank
5. Fuel supply line Mark before removing To disconnect, press release button on connection piece Do not bend Note direction of arrow (fuel supply or return) on connector flange when installing Clipped in on fuel tank
6. Electrical harness connector for Fuel Pump (FP) and sender for fuel gauge -G- Releasing. See «RELEASING HARNESS CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__releasing-harness-connector) .
7. Union nut -80 N.m Use ring nut wrench 3217 to remove and install
8. Suction jet pipe To disconnect, press release button on connection piece
9. Suction jet pump

Releasing harness connector

1. To disconnect the multi-pin harness connector at Fuel Pump (FP), the harness connector must be released. This can be done by hand or by using a small screwdriver -arrow-.

Fuel pump, removing and installing

Recommended special tools and equipment

1. 3217 ring nut wrench
2. VAS5190 fuel siphoning device

Empty fuel tank

Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY SYSTEM .

Observe rules for cleanliness. See RULES OF CLEANLINESS .

See BATTERY DISCONNECT PRECAUTIONS .

1. Disconnect battery Ground (GND) strap with the ignition switched off. CAUTION: Secure Ground (GND) wire of VAS5190 to a blank portion of the chassis.
2. Pull cone piece -2- from shaft piece -1- of VAS 5190.
3. Using insulating tape, apply a mark -arrow- on hose at length a = 1465 mm from end of suction hose.
4. Remove fuel filler cap from fuel filler tube.
5. Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
6. Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

Note. If using a siphoning device without shaft piece, proceed principally in the same manner. In this case, apply a mark -arrow- on hose at length a = 1400 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube. If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube.
2. Carefully remove siphoning hose.

Sedan

1. Remove luggage compartment lining.
2. Push forward the right backrest of rear seat, if necessary.

Avant

1. Remove left 1/3 backrest. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim in luggage compartment and dirt tray. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) and «DIRT TRAY, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .

All

1. Remove cover for connector flange (arrows).
2. Release and disconnect harness connector -1-.
3. Disengage electrical harness connector -2- and lay it aside.

1. Mark and disconnect fuel supply line -1- and fuel return line -2- (press release tab).
2. Use ring nut wrench 3217 to remove union nut.
3. Lift out fuel pump with sealing ring slightly from opening of fuel tank
4. If Fuel Pump (FP) is still inserted in fuel tank, slide connector flange slightly to the side.
5. Grasp through the gap between connector flange and installation opening in fuel tank and release suction jet pump -1-.

Note. Fuel tank is depicted as cut-out section.

1. Pull suction jet pump -1- upward with suction jet pipe -2- still connected.
2. Disconnect suction jet pipe from suction jet pump (press release button).
3. Remove suction jet pump.
4. Remove Fuel Pump (FP).

Installing

Installation is the reverse of removal, noting the following

1. Connect suction jet pipe -2- to connection for suction jet pump -1-.
2. Insert Fuel Pump (FP) into fuel tank.
3. Clip in suction jet pump -1- on Fuel Pump (FP). To do so, insert hand into gap between connector flange and installation opening of fuel tank. Suction jet pump must engage audibly
4. Insert new, dry seal for connector flange into opening of fuel tank.
5. Note installation position of Fuel Pump (FP): Marking on connector flange -2- must align with marking on fuel tank -1-.
6. Tighten union nut for connector flange.
7. Install fuel supply line -1- and fuel return line -2- according to the marking.
8. Connect electrical harness connectors.
9. Observe safety precautions after connecting the battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/charging-system/#generators-regulators) .

Tightening torques

TIGHTENING TORQUES: FUEL PUMP UNION NUT (FWD - VEHICLES UP TO 06.2003)

Final procedures

After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence

1. Vent fuel system. See «FUEL SYSTEM, BLEEDING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb) .
2. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
3. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
4. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

1. VAG1348/3A remote control with VAG1348/3-2 adapter cable
2. VAG1526A hand multimeter
3. VAG1594A connector test kit

Test requirements

1. Battery voltage at least 12.5 V
2. Fuse S228 OK (position 28)
3. Fuel Pump (FP) Relay OK; checking. See «FUEL PUMP (FP) RELAY -J17- AND ACTIVATION, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-fp-relay-j17-and) .
4. Fuel filter OK
5. Ignition switched off.

Test sequence

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect e.g. VAG1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Press switch of remote control. Operating noise of the pump must be audible in vicinity of fuel tank.

Note. Fuel Pump (FP) runs quietly. Surrounding noise should be avoided during test of the Fuel Pump (FP).

no operating noise can be heard

1. Remove luggage compartment lining.
2. Push forward the right backrest of rear seat, if necessary.

1. Remove left 1/3 backrest. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim in luggage compartment and dirt tray. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) and «DIRT TRAY, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .

1. Remove cover for connector flange (arrows).
2. Release and disconnect harness connector -1-.
3. Connect multimeter between terminal 1 and 4 of harness connector for voltage measurement.
4. Press switch of remote control. Specified value: approx. battery voltage

If specified value is obtained, although no operating noise can be heard from pump

1. Remove fuel pump. See «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-removing-and-installing) .
2. Check whether electrical wires between flange and Fuel Pump (FP) are connected, and test for continuity if necessary.

If no malfunction is detected in wires, Fuel Pump (FP) is faulty - replace fuel pump.

1. Install Fuel Pump (FP). See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__installing) .

After repair work, the following work steps must be performed in the mentioned sequence

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

1. V.A.G 1318/17-1 adapter
2. VAG1348/3A remote control with VAG1348/3-2 adapter cable
3. Measuring container, fuel-tight

1. Battery voltage at least 12.5 V
2. Fuel filter OK
3. Ignition switched off.

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect e.g. VAG1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Remove fuel filler cap from fuel filler tube.

1. Remove luggage compartment lining.
2. Push forward the right backrest of rear seat, if necessary.

1. Remove left 1/3 backrest. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim in luggage compartment and dirt tray. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) and «DIRT TRAY, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .

1. Remove cover for connector flange (arrows).

1. Disconnect fuel return line -2- (press release button).

Note. Fuel supply line -1- remains connected.

1. Connect V.A.G 1318/17-1 adapter to disconnected fuel return line and hold in a measuring container.
2. Operate remote control for 15 seconds (keep button pressed).
3. Compare fuel quantity pumped with specified value.

*) Minimum delivery rate cm 3 /15 sec

**) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage).

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. Fuel lines pinched
2. Fuel filter clogged
3. Fuel pump faulty

Assembly is performed in the reverse order of removal, noting the following

1. Install fuel return line.

Fuel supply system - Front Wheel Drive (FWD) - Vehicles as of 07.2003

Note. Secure all hose connections using hose clamps appropriate for the model type. VAG1921 hose clip pliers are recommended for installing spring-type clamps. Always replace seals and gaskets.

Note. The following list refers to see scheme 34.

1. Fuel supply line from fuel filter To engine Do not bend To disconnect, press release button on connection piece
2. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Do not bend To disconnect, press release button on connection piece Clipped in on fuel tank
3. Electrical harness connector for Fuel Tank Lock Switch -F314
4. 2 N.m
5. Heat shield for fuel filler tube
6. 23 N.m serves to secure fuel filler tube and Ground (GND) connection (item 12)
7. Overflow hose engage in wheelhouse
8. Rubber pan
9. Tensioning ring
10. Seal Replace if damaged
11. Cap
12. Ground (GND) connection For discharging electrostatic charge Installed position / check requirements. See «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Ensure secure seating of connector and secure wire with securing bolt for fuel filler tube (item 6) After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter. Specified value: approx. 0 ohm
13. Vent line
14. Vent line from gravity valve to EVAP canister To remove, press release ring on EVAP canister
15. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clipped in on fuel tank
16. Fuel tank
17. Heat shield for fuel tank
18. 2 N.m
19. Heat shield for fuel tank
20. 2 N.m
21. Expanding clip
22. Tension strap Note varying lengths
23. 23 N.m

1. Route Ground (GND) connection see scheme 35
2. First, engage contact -1- of Ground (GND) connection into securing opening on fuel tank -5- and then press in spacer bushing -2-.
3. Ensure connector -4- of Ground (GND) connection fits securely at metal ring -3- of fuel filler tube.

Scheme 209

Note. The following list refers to see scheme 36.

1. Sender for fuel gauge -G
2. Fuel pump Check Fuel Pump (FP) electrically. See «CHECKING FUEL PUMP ELECTRICALLY»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking delivery quantity. See «DELIVERY QUANTITY OF FUEL PUMP (FP), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking residual pressure. See «SYSTEM PRESSURE AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__system-pressure-and-residual-pressure-checking) . Removing and installing. See «REMOVING AND INSTALLING FUEL PUMP»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__removing-and-installing-fuel-pump) .
3. Seal replace to install, place into opening of fuel tank dry
4. Fuel return line from fuel filter Mark before removing To disconnect, press release button on connection piece Do not bend Note direction of arrow (fuel supply or return) on connector flange when installing Clipped in on fuel tank
5. Ventilation line from fuel pressure regulator in fuel filter To disconnect, press release button on connection piece Do not bend Clipped in on fuel tank
6. Fuel supply line To fuel filter Mark before removing To disconnect, press release button on connection piece Do not bend Note direction of arrow (fuel supply or return) on connector flange when installing Clipped in on fuel tank
7. Electrical harness connector for Fuel Pump (FP) and sender for fuel gauge -G- Disengaging. See «RELEASING HARNESS CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
8. Locking ring Use ring nut wrench 3087 to remove and install Tighten to 145 N.m
9. Suction jet pipe To disconnect, press release button on connection piece
10. Suction jet pump

1. To disconnect the multi-pin harness connector at Fuel Pump (FP), the harness connector must be released. This can be done by hand or by using a small screwdriver -arrow-.

Removing and installing fuel pump

1. 3087 wrench for tank sensor
2. VAS5190 fuel siphoning device

Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY SYSTEM .

Observe rules for cleanliness. See RULES OF CLEANLINESS .

See BATTERY DISCONNECT PRECAUTIONS .

1. Disconnect battery Ground (GND) strap with the ignition switched off.

1. Pull cone piece -2- from shaft piece -1- of VAS 5190.
2. Using insulating tape, apply a mark -arrow- on hose at length a = 1465 mm from end of suction hose.
3. Remove fuel filler cap from fuel filler tube.
4. Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
5. Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

Note. If using a siphoning device without shaft piece, proceed principally in the same manner. In this case, apply a mark -arrow- on hose at length a = 1400 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube. If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube.
2. Carefully remove siphoning hose.

1. Remove luggage compartment lining.
2. Push forward the right backrest of rear seat, if necessary.

1. Remove left 1/3 backrest. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim in luggage compartment and dirt tray. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) and «DIRT TRAY, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .

1. Remove cover for connector flange (arrows).
2. Release and disconnect harness connector -1-.
3. Disengage electrical harness connector -2- and lay it aside.

1. Mark and disconnect fuel supply line -1- and fuel return line -3- (press release tab).
2. Disconnect ventilation line -2- (press release button).
3. Use e.g. 3087 wrench to remove locking ring.
4. Lift out fuel pump with sealing ring slightly from opening of fuel tank
5. If Fuel Pump (FP) is still inserted in fuel tank, slide connector flange slightly to the side.
6. Grasp through the gap between connector flange and installation opening in fuel tank and release suction jet pump -1-.

Note. Fuel tank is depicted as cut-out section.

1. Pull suction jet pump -1- upward with suction jet pipe -2- still connected.
2. Disconnect suction jet pipe from suction jet pump (press release button).
3. Remove suction jet pump.
4. Remove Fuel Pump (FP).

Installation is the reverse of removal, noting the following

1. Connect suction jet pipe -2- to connection for suction jet pump -1-.
2. Insert Fuel Pump (FP) into fuel tank.
3. Clip in suction jet pump -1- on Fuel Pump (FP). To do so, insert hand into gap between connector flange and installation opening of fuel tank. Suction jet pump must engage audibly
4. Insert new, dry seal for connector flange into opening of fuel tank.
5. Note installation position of Fuel Pump (FP): The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

Note. Arrow points in direction of travel.

1. Tighten locking ring.
2. Install fuel supply line -1- and fuel return line -3- according to the marking.
3. Install ventilation line -2-.
4. Connect electrical harness connectors.
5. Observe safety precautions after connecting the battery.

See BATTERY DISCONNECT PRECAUTIONS .

TIGHTENING TORQUES: FUEL PUMP LOCKING RING (FWD - VEHICLES AS OF 07.2003)

After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence

1. Vent fuel system. See «FUEL SYSTEM, BLEEDING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb) .
2. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
3. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
4. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

Special Tools and Equipment

1. VAG1348/3A remote control with VAG1348/3-2 adapter cable
2. VAG1526A hand multimeter
3. VAG1594A connector test kit

1. Battery voltage at least 12.5 V
2. Fuse S228 OK (position 28)
3. Fuel Pump (FP) Relay OK; checking. See «FUEL PUMP (FP) RELAY -J17- AND ACTIVATION, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-fp-relay-j17-and) .
4. Fuel filter OK
5. Ignition switched off.

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect e.g. VAG1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Press switch of remote control. Operating noise of the pump must be audible in vicinity of fuel tank.

Note. Fuel Pump (FP) runs quietly. Surrounding noise should be avoided during test of the Fuel Pump (FP).

If no operating noise can be heard

1. Remove luggage compartment lining.
2. Push forward the right backrest of rear seat, if necessary.

1. Remove left 1/3 backrest. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim in luggage compartment and dirt tray. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) and «DIRT TRAY, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .

1. Remove cover for connector flange (arrows).
2. Release and disconnect harness connector -1-.
3. Connect multimeter between terminal 1 and 4 of harness connector for voltage measurement.
4. Press switch of remote control. Specified value: approx. battery voltage

If specified value is not obtained

1. Repair open circuit in wiring according to wiring diagram.

If specified value is obtained, although no operating noise can be heard from pump

1. Remove fuel pump. See «REMOVING AND INSTALLING FUEL PUMP»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__removing-and-installing-fuel-pump) .
2. Check whether electrical wires between flange and Fuel Pump (FP) are connected, and test for continuity if necessary.

If no malfunction is detected in wires, Fuel Pump (FP) is faulty - replace fuel pump.

1. Install Fuel Pump (FP). See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .

1. V.A.G 1318/17-1 adapter
2. VAG1348/3A remote control with VAG1348/3-2 adapter cable
3. Measuring container, fuel-tight

1. Battery voltage at least 12.5 V
2. Fuel filter OK
3. Fuel tank at least 1/4 filled.
4. Fuel pressure regulator OK, checking

See CHECKING FUEL PRESSURE REGULATOR -- VEHICLES WITH FRONT-WHEEL DRIVE and CHECKING FUEL PRESSURE REGULATOR -- VEHICLES WITH ALL WHEEL DRIVE .

1. Ignition switched off.

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect e.g. VAG1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Remove fuel filler cap from fuel filler tube.

1. Remove luggage compartment lining.
2. Push forward the right backrest of rear seat, if necessary.

1. Remove left 1/3 backrest. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim in luggage compartment and dirt tray. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) and «DIRT TRAY, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .

1. Remove cover for connector flange (arrows).

1. Disconnect fuel return line (arrow) (press release button).
2. Connect e.g. V.A.G 1318/17 -1 adapter to disconnected fuel return line and hold in a measuring container.
3. Operate remote control for 15 seconds (keep button pressed).
4. Compare fuel quantity pumped with specified value.

*) Minimum delivery rate cm 3 /15 s

**) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage).

1. Fuel lines pinched
2. Fuel filter clogged
3. Fuel pump faulty

Assembly is performed in the reverse order of removal, noting the following

1. Install fuel return line.

Fuel supply system - All Wheel Drive (AWD) - Vehicles up to 06.2003

Note. Secure all hose connections using hose clamps appropriate for the model type. VAG1921 hose clip pliers are recommended for installing spring-type clamps. Always replace seals and gaskets.

Note. The following list refers to see scheme 65.

1. Bracket for exhaust system
2. Carrier plate
3. Fuel supply line from fuel filter To engine Do not bend To disconnect, press release button on connection piece
4. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Do not bend To disconnect, press release button on connection piece Clipped in on fuel tank
5. not installed
6. Electrical harness connector For fuel tank lock switch
7. 2 N.m
8. Heat shield
9. 23 N.m Serves to secure fuel filler neck and Ground (GND) connection. See item 15 .
10. Overflow hose
11. Rubber pan
12. Tensioning ring
13. Seal Replace if damaged
14. Cap
15. Ground (GND) connection For discharging electrostatic charge Installed position / check requirements. See «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Ensure secure seating of connector and secure wire with securing bolt for fuel filler tube. See item 9 . After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter. Specified value: approx. 0 ohm
16. Vent line
17. Spring clip
18. Vent line from gravity valve to EVAP canister To remove, press release ring on EVAP canister
19. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clipped in on fuel tank
20. Fuel tank Empty if necessary, to remove components. See «EMPTY FUEL TANK»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
21. Tension strap
22. Expanding clip
23. 23 N.m
24. Heat shield for fuel tank
25. 2 N.m
26. 23 N.m

1. Route Ground (GND) connection see scheme 66
2. First, engage contact -1- of Ground (GND) connection into securing opening on fuel tank -4-.
3. Ensure connector -3- of Ground (GND) connection fits securely at metal ring -2- of fuel filler tube.

Scheme 210

Part I

Note. The following list refers to see scheme 67.

1. Sender for fuel gauge -G- Clipped in at baffle housing in fuel tank
2. Fuel pump Different versions, allocation Can be replaced only complete with connector flange Check Fuel Pump (FP) electrically. See «FUEL PUMP (FP), ELECTRICAL TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking delivery quantity. See «DELIVERY QUANTITY OF FUEL PUMP (FP), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking residual pressure. See «SYSTEM PRESSURE AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__system-pressure-and-residual-pressure-checking) . Removing and installing. See «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
3. Electrical harness connector for Fuel Pump (FP) and sender for fuel gauge -G- Releasing. See «RELEASING HARNESS CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
4. Connector flange For Fuel Pump (FP) not individually replaceable Installation position. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
5. Seal replace to install, place into opening of fuel tank dry
6. Locking ring Use ring nut wrench 3087 to remove and install Tighten to 145 N.m
7. Fuel supply line To fuel filter To disconnect, press release button on connection piece Do not bend Clipped in on fuel tank
8. Union piece Different versions, allocation. Clipped in on baffle housing with catches To remove, press toward right so that catches disengage and lift upward
9. Fuel line To suction jet pump in baffle housing
10. Fuel return line From connector flange, left side
11. Fuel delivery line From suction jet pump, right side
12. Baffle housing With suction jet pump

Part II

Note. The following list refers to see scheme 68.

1. Baffle housing With suction jet pump
2. Union piece Different versions, allocation. Clipped in on baffle housing with catches To remove, press toward right so that catches disengage and lift upward
3. Fuel line To suction jet pump in baffle housing
4. Fuel return line From connector flange, left side
5. Fuel return line From engine / from fuel filter To disconnect, press release button on connection piece Do not bend Clipped in on fuel tank
6. Seal replace to install, place into opening of fuel tank dry
7. Locking ring Use ring nut wrench 3087 to remove and install Tighten to 145 N.m
8. Electrical harness connector For Fuel Level Sensor 2 -G169- Releasing. See «RELEASING HARNESS CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
9. Connector flange Only available together with -item 10- Installation position. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
10. Fuel Level Sensor 2 -G169- Only available together with -item 9
11. Suction jet pump With lines Different versions, allocation. Secured on connector flange
12. Fuel delivery line From suction jet pump, right side

1. To disconnect the multi-pin harness connector at Fuel Pump (FP), the harness connector must be released. This can be done by hand or by using a small screwdriver -arrow-.

1. 3087 wrench for tank sensor
2. Fuel Pump Wrench 3307
3. VAS5190 fuel siphoning device

Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY SYSTEM .

Observe rules for cleanliness. See RULES OF CLEANLINESS .

See BATTERY DISCONNECT PRECAUTIONS .

1. Disconnect battery Ground (GND) strap with the ignition switched off.

1. Pull cone piece -2- from shaft piece -1- of VAS 5190.
2. Using insulating tape, apply a mark -arrow- on hose at length a = 1,865 mm from end of suction hose.
3. Remove fuel filler cap from fuel filler tube.
4. Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
5. Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

Note. If using a siphoning device without shaft piece, proceed principally in the same manner. In this case, apply a mark -arrow- on hose at length a = 1,800 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube. If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube as much as possible.
2. Carefully remove siphoning hose.
3. Remove rear seat bench. See «SEATBENCH, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet__seatbench-removing-and-installing) (except Cabriolet) , and for Cabriolet see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Remove cover for right connector flange (arrows).
5. Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
6. Disengage electrical harness connector -2- and lay it aside.

1. Disconnect fuel supply line (arrow) from connector flange (right side of vehicle).
2. Use e.g. 3087 wrench to remove locking ring.
3. Pull connector flange and sealing ring from opening of fuel tank.
4. Disconnect harness connector -arrow- to fuel gauge on the inside of connector flange.
5. Slide suction hose for a length of dimension x = 800 mm through right opening on fuel tank to left tank chamber.
6. Empty left fuel tank chamber.

Removing

1. Disconnect harness connector -arrow- to fuel gauge on the inside of connector flange.
2. Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
3. Rotate Fuel Pump (FP) toward left approx. 15° to stop. Notch -1- aligns with marking -2- (bayonet connection)
4. Remove Fuel Pump (FP).

Installation is the reverse of removal, noting the following

1. Insert new, dry seal for connector flange from fuel level sensor 2 into opening of fuel tank.
2. Note the installation position of connector flange from fuel level sensor 2: The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

Note. Arrow points in direction of travel.

Scheme 211

1. Tighten locking ring to 145 N.m.
2. Insert Fuel Pump (FP) into baffle housing in tank so that the notch -1- at the Fuel Pump (FP) aligns with the marking -2- at the baffle housing. Fuel Pump (FP) can be pressed downward significantly and noticeably
3. Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
4. Rotate Fuel Pump (FP) toward right approx. 15° to stop. Notch -1- aligns with marking -3- (bayonet connection)
5. Connect harness connector -arrow- for fuel gauge on inside of connector flange.
6. Insert new, dry seal for connector flange into opening of fuel tank.
7. Note installation position of connector flange: The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

Note. Arrow points in direction of travel.

1. Tighten locking ring.
2. Observe safety precautions after connecting the battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/charging-system/#generators-regulators) .

TIGHTENING TORQUES: FUEL PUMP LOCKING RING (AWD - VEHICLES UP TO 06.2003)

After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence

1. Vent fuel system. See «FUEL SYSTEM, BLEEDING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb) .
2. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
3. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
4. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

1. VAG1348/3A remote control with VAG1348/3-2 adapter cable
2. VAG1526A hand multimeter
3. VAG1594A connector test kit

1. Battery voltage at least 12.5 V
2. Fuse S228 OK (position 28)
3. Fuel Pump (FP) Relay OK; checking. See «FUEL PUMP (FP) RELAY -J17- AND ACTIVATION, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-fp-relay-j17-and) .
4. Fuel filter OK
5. Ignition switched off.

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect V.A.G 1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Press switch of remote control. Operating noise of the pump must be audible in vicinity of fuel tank.

Note. Fuel Pump (FP) runs quietly. Surrounding noise should be avoided during test of the Fuel Pump (FP).

If no operating noise can be heard

1. Remove rear seat bench. See «SEATBENCH, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet__seatbench-removing-and-installing) (except Cabriolet), or for Cabriolet see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
2. Remove cover for right connector flange (arrows).
3. Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
4. Connect multimeter between terminal 1 and 4 of harness connector for voltage measurement.
5. Press switch of remote control. Specified value: approx. battery voltage

If specified value is obtained, although no operating noise can be heard from pump

1. Remove fuel pump. See «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
2. Check whether electrical wires between flange and Fuel Pump (FP) are connected, and test for continuity if necessary.

If no malfunctions are found in wires

1. Fuel Pump (FP) faulty, replace fuel pump. See «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
2. Install Fuel Pump (FP). See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .

After repair work, the following work steps must be performed in the mentioned sequence

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

1. V.A.G 1318/17-1 adapter
2. VAG1348/3A remote control with VAG1348/3-2 adapter cable
3. Measuring container, fuel-tight

1. Battery voltage at least 12.5 V
2. Fuel filter OK
3. Ignition switched off.

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect e.g. VAG1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Remove fuel filler cap from fuel filler tube.
6. Remove rear seat bench.

See SEATBENCH, REMOVING AND INSTALLING (except Cabriolet), or for Cabriolet see REAR SEAT BENCH, ASSEMBLY OVERVIEW .

1. Remove cover for left connector flange (arrows).

1. Disconnect fuel return line (arrow) from connector flange (left side of vehicle).
2. Connect V.A.G 1318/17-1 adapter to disconnected fuel return line and hold in a measuring container.
3. Operate remote control for 15 seconds (keep button pressed).
4. Compare fuel quantity pumped with specified value.

*) Minimum delivery rate cm 3 /15 s

**) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage).

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. Fuel lines pinched
2. Fuel filter clogged
3. Fuel pump faulty

Assembly is performed in the reverse order of removal, noting the following

1. Install fuel return line.

Fuel supply system - All Wheel Drive (AWD) - Vehicles as of 07.2003

Note. Secure all hose connections using hose clamps appropriate for the model type. VAG1921 hose clip pliers are recommended for installing spring-type clamps. Always replace seals and gaskets.

Note. The following list refers to see scheme 106.

1. Bracket for exhaust system
2. Carrier plate
3. Fuel supply line from fuel filter To engine Do not bend To disconnect, press release button on connection piece
4. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Do not bend To disconnect, press release button on connection piece Clipped in on fuel tank
5. Electrical harness connector for Fuel Tank Lock Switch -F314
6. 2 N.m
7. Heat shield for fuel filler tube
8. 23 N.m serves to secure fuel filler tube and Ground (GND) connection (item 14)
9. Overflow hose
10. Rubber pan
11. Tensioning ring
12. Seal Replace if damaged
13. Cap
14. Ground (GND) connection For discharging electrostatic charge Installed position / check requirements. See «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Ensure secure seating of connector and secure wire with securing bolt for fuel filler tube (item 8) After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter. Specified value: approx. 0 ohm
15. Vent line
16. Vent line from gravity valve to EVAP canister To remove, press release ring on EVAP canister
17. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clipped in on fuel tank
18. Fuel tank
19. Expanding clip
20. 23 N.m
21. Tension strap
22. Heat shield for fuel tank
23. 2 N.m
24. 23 N.m

1. Route Ground (GND) connection see scheme 107
2. First, engage contact -1- of Ground (GND) connection into securing opening on fuel tank -5- and then press in spacer bushing -2-.
3. Ensure connector -4- of Ground (GND) connection fits securely at metal ring -3- of fuel filler tube.

Note. The following list refers to see scheme 108.

1. Sender for fuel gauge -G- Clipped in at baffle housing in fuel tank
2. Fuel pump Different versions, allocation. Can be replaced only complete with connector flange Check Fuel Pump (FP) electrically. See «CHECKING FUEL PUMP ELECTRICALLY»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking fuel delivery. See «DELIVERY QUANTITY OF FUEL PUMP (FP), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Checking residual pressure. See «SYSTEM PRESSURE AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__system-pressure-and-residual-pressure-checking) . Removing and installing. See «REMOVING AND INSTALLING FUEL PUMP»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
3. Electrical harness connector for Fuel Pump (FP) and sender for fuel gauge -G- Disengaging. See «RELEASING HARNESS CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
4. Connector flange For Fuel Pump (FP) not individually replaceable Installation position. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
5. Ventilation line from fuel pressure regulator in fuel filter To disconnect, press release button on connection piece Do not bend Clipped in on fuel tank
6. Seal replace to install, place into opening of fuel tank dry
7. Locking ring Use ring nut wrench 3087 to remove and install Tighten to 145 N.m
8. Fuel supply line To fuel filter To disconnect, press release button on connection piece Do not bend Clipped in on fuel tank
9. Union piece Different versions, allocation. Clipped in on baffle housing with catches To remove, press toward right so that catches disengage and lift upward
10. Fuel line To suction jet pump in baffle housing
11. Fuel return line From connector flange, left side
12. Fuel delivery line From suction jet pump, right side
13. Baffle housing With suction jet pump

Note. The following list refers to see scheme 109.

1. Baffle housing With suction jet pump
2. Union piece Different versions, allocation. Clipped in on baffle housing with catches To remove, press toward right so that catches disengage and lift upward
3. Fuel line To suction jet pump in baffle housing
4. Fuel return line From connector flange, left side
5. Fuel return line from fuel filter To disconnect, press release button on connection piece Do not bend Clipped in on fuel tank
6. Seal replace to install, place into opening of fuel tank dry
7. Locking ring Use ring nut wrench 3087 to remove and install Tighten to 145 N.m
8. Electrical harness connector for Fuel Level Sensor 2 -G169- Disengaging. See «RELEASING HARNESS CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
9. Connector flange only available together with -item 10- Installation position. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
10. Fuel Level Sensor 2 -G169- only available together with -item 9
11. Suction jet pump With lines Different versions, allocation Secured on connector flange
12. Fuel delivery line From suction jet pump, right side

1. To disconnect the multi-pin harness connector at Fuel Pump (FP), the harness connector must be released. This can be done by hand or by using a small screwdriver -arrow-.

1. 3087 wrench for tank sensor
2. Fuel Pump Wrench 3307
3. VAS5190 fuel siphoning device

Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY SYSTEM .

Observe rules for cleanliness. See RULES OF CLEANLINESS .

See BATTERY DISCONNECT PRECAUTIONS .

1. Disconnect battery Ground (GND) strap with the ignition switched off.

1. Pull cone piece -2- from shaft piece -1- of VAS 5190.
2. Using insulating tape, apply a mark -arrow- on hose at length a = 1,865 mm from end of suction hose.
3. Remove fuel filler cap from fuel filler tube.
4. Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
5. Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

Note. If using a siphoning device without shaft piece, proceed principally in the same manner. In this case, apply a mark -arrow- on hose at length a = 1,800 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube. If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube as much as possible.
2. Carefully remove siphoning hose.
3. Remove rear seat bench.

See SEATBENCH, REMOVING AND INSTALLING (except Cabriolet), or for Cabriolet see REAR SEAT BENCH, ASSEMBLY OVERVIEW .

1. Remove cover for right connector flange (arrows).
2. Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
3. Disengage electrical harness connector -2- and lay it aside.

1. Disconnect fuel supply line -1- from connector flange (right side of vehicle).
2. Disconnect ventilation line -2- (press release button).
3. Use 3087 wrench to remove locking ring.
4. Pull connector flange and sealing ring from opening of fuel tank.
5. Disconnect harness connector -arrow- to fuel gauge on the inside of connector flange.
6. Slide suction hose for a length of dimension x = 800 mm through right opening on fuel tank to left tank chamber.
7. Empty left fuel tank chamber.
8. Remove rear seat bench.

See SEATBENCH, REMOVING AND INSTALLING (except Cabriolet), or for Cabriolet see REAR SEAT BENCH, ASSEMBLY OVERVIEW .

1. Remove cover for right connector flange (arrows).
2. Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
3. Disengage electrical harness connector -2- and lay it aside.

1. Disconnect fuel supply line -1- and ventilation line -2- from connector flange (right side of vehicle) (press release button).
2. Use e.g. 3087 wrench to remove locking ring.
3. Pull connector flange and sealing ring from opening of fuel tank.
4. Disconnect harness connector -arrow- to fuel gauge on the inside of connector flange.
5. Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
6. Rotate Fuel Pump (FP) toward left approx. 15° to stop. Notch -1- aligns with marking -2- (bayonet connection)
7. Remove Fuel Pump (FP).

Installation is the reverse of removal, noting the following

1. Insert new, dry seal for connector flange of fuel level sensor 2 into opening of fuel tank.
2. Note the installation position of connector flange of fuel level sensor 2: The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

Note. Arrow points in direction of travel.

Scheme 212

1. Tighten locking ring.
2. Insert Fuel Pump (FP) into baffle housing in tank so that the notch -1- at the Fuel Pump (FP) aligns with the marking -2- at the baffle housing. Fuel Pump (FP) can be pressed downward significantly and noticeably
3. Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
4. Rotate Fuel Pump (FP) toward right approx. 15° to stop. Notch -1- aligns with marking -3- (bayonet connection)
5. Connect harness connector -arrow- for fuel gauge on inside of connector flange.
6. Insert new, dry seal for connector flange into opening of fuel tank.
7. Note installation position of connector flange: The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

Note. Arrow points in direction of travel.

1. Tighten locking ring.
2. Observe safety precautions after connecting the battery.

See BATTERY DISCONNECT PRECAUTIONS .

TIGHTENING TORQUES: FUEL PUMP LOCKING RING (AWD - VEHICLES AS OF 07.2003)

After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence

1. Vent fuel system. See «FUEL SYSTEM, BLEEDING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb) .
2. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
3. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
4. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

1. VAG1348/3A remote control with VAG1348/3-2 adapter cable
2. VAG1526A hand multimeter
3. VAG1594A connector test kit

1. Battery voltage at least 12.5 V
2. Fuse S228 OK (position 28)
3. Fuel Pump (FP) Relay OK; checking. See «FUEL PUMP (FP) RELAY -J17- AND ACTIVATION, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-fp-relay-j17-and) .
4. Fuel filter OK
5. Ignition switched off.

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect e.g. VAG1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Press switch of remote control. Operating noise of the pump must be audible in vicinity of fuel tank.

Note. Fuel Pump (FP) runs quietly. Surrounding noise should be avoided during test of the Fuel Pump (FP).

If no operating noise can be heard

1. Remove rear seat bench.

See SEATBENCH, REMOVING AND INSTALLING (except Cabriolet), or for Cabriolet see REAR SEAT BENCH, ASSEMBLY OVERVIEW .

1. Remove cover for right connector flange (arrows).
2. Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
3. Connect multimeter between terminal 1 and 4 of harness connector for voltage measurement.
4. Press switch of remote control. Specified value: approx. battery voltage

If specified value is not obtained

1. Repair open circuit in wiring according to wiring diagram.

If specified value is obtained, although no operating noise can be heard from pump

1. Remove fuel pump. See «REMOVING AND INSTALLING FUEL PUMP»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
2. Check whether electrical wires between flange and Fuel Pump (FP) are connected, and test for continuity if necessary.

If no malfunction is detected in wires, Fuel Pump (FP) is faulty - replace fuel pump.

1. Install Fuel Pump (FP). See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .

1. V.A.G 1318/17-1 adapter
2. VAG1348/3A remote control with VAG1348/3-2 adapter cable
3. Measuring container, fuel-tight

1. Battery voltage at least 12.5 V
2. Fuel filter OK
3. Fuel tank at least 1/4 filled.
4. Fuel pressure regulator OK, checking
5. Ignition switched off.

1. Open cover of fuse box at left side of instrument cluster.
2. Remove fuse S228 at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect e.g. VAG1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from fuse S228 (position 28).
4. Connect alligator clip to vehicle battery B+.
5. Remove fuel filler cap from fuel filler tube.
6. Remove rear seat bench. See «SEATBENCH, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet__seatbench-removing-and-installing) (except Cabriolet), or for Cabriolet see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
7. Remove cover for left connector flange (arrows).

1. Disconnect fuel return line (arrow) from connector flange (left side of vehicle).
2. Connect e.g. V.A.G 1318/17-1 adapter to disconnected fuel return line and hold in a measuring container.
3. Operate remote control for 15 seconds (keep button pressed).
4. Compare fuel quantity pumped with specified value.

*) Minimum delivery rate cm 3 /15 s

**) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage).

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. Fuel lines pinched
2. Fuel filter clogged
3. Fuel pump faulty

Assembly is performed in the reverse order of removal, noting the following

1. Install fuel return line.

EVAP canister/leak detection system - component overview

Note. The following list refers to see scheme 151.

1. Cap nut -9 N.m
2. Cover For EVAP canister
3. Stud bolt -16 N.m
4. Sealing piece
5. Vent line From gravity valve at fuel tank To remove, press release ring on EVAP canister
6. Vent line to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister
7. Air filter housing for Leak Detection Pump (LDP) -V144- no maintenance procedure
8. 4 N.m
9. Vacuum line to Leak Detection Pump (LDP) -V144
10. Cable tie for securing vacuum line to Leak Detection Pump (LDP) bracket
11. Leak Detection Pump (LDP) -V144- Component location: Under wheel housing liner in rear left wheelhouse Checking. See «LEAK DETECTION PUMP (LDP) -V144-, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) .
12. Electrical harness connector Black
13. Connection hose Leak Detection Pump (LDP)/EVAP canister Pressure side to remove, press release button at connection on Leak Detection Pump (LDP)
14. Connection hose Leak Detection Pump (LDP)/air filter
15. Cable tie for securing hose to Leak Detection Pump (LDP) bracket
16. Sealing piece
17. Cable tie for securing connection hose to wheel housing
18. EVAP canister Component location: Bottom of spare wheel well Removing and installing. See «EVAP CANISTER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__evap-canister-removing-and-installing) .

EVAP canister, removing and installing

1. Remove EVAP canister cover at bottom of spare wheel well.
2. Remove sealing pieces above ventilation lines.
3. Remove hose connection -1- at ventilation line.
4. Disconnect ventilation lines -2- and -3-. To do so, press release ring -4- in direction of arrow -A- and pull off ventilation line (arrow -B-).
5. Remove pin bolts (arrows) and remove EVAP canister.

Installation is the reverse of removal, noting the following

Note. Secure all hose connections using hose clamps appropriate for the model type.

TIGHTENING TORQUES: EVAP CANISTER

Hose plan, EVAP canister system / Leak detection system

Note. The following list refers to see scheme 153.

1. Check-valve Installation position (light/dark side): Arrow on valve points in direction of flow, as shown in illustration.
2. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Component location: Front right in engine compartment
3. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Installation position: Right side, beneath vehicle floor secured to fuel tank in fuel tank area
4. Vent line to gravity valve on fuel tank
5. EVAP canister Component location: Bottom of spare wheel well
6. Connection hose Leak Detection Pump (LDP)/EVAP canister Pressure side
7. Air filter housing for Leak Detection Pump (LDP) -V144
8. Leak Detection Pump (LDP) -V144- Component location: Under wheel housing liner in rear left wheelhouse
9. Vacuum line Leak Detection Pump (LDP)/throttle valve control module
10. Check-valves Installation position (light/dark side): Arrow on valve points in direction of flow, as shown in illustration.
11. T-piece Component location. See «COMPONENT LOCATION OF T-PIECE»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__component-location-of-t-piece) .
12. Throttle valve control module -J338

Component location of T-piece

T-piece (arrow) is located on the left in engine compartment.

Scheme 213

Function

The evaporative emissions (EVAP) system, diagnostic leak test recognizes leaks in the entire fuel system including the fuel tank, Evaporative Emission (EVAP) canister and Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-.

On the mechanical side, the leak detection system consists primarily of a vacuum activated diaphragm pump with a reed contact on an activating rod at the pump diaphragm. The pump is supplied with vacuum via the engine intake stroke.

1. When diagnostic leak test is activated, the Leak Detection Pump (LDP) increases pressure in the fuel system to 20 to 30 mbar. The pump membrane is then moved out so that the reed contact at the operating rod remains in the "open" position.
2. The diagnostic will test whether the reed contact remains open within 10 seconds. Then the fuel system is leak-free.
3. If pressure falls (indicating a leak), the diaphragm moves back and the reed contact closes.
4. If reed contact closes within 10 seconds of leak detection time, a further test is performed: If this is the case, the membrane pump will pump 4 additional strokes. The Engine Control Module (ECM) measures the time between these 4 strokes and closure of the reed contact. From that, the control module can recognize a "small leak" (greater than 1 mm in diameter) or a "large leak".

Leak diagnostic is activated automatically shortly following every engine start. If a malfunction is recognized, a DTC entry follows. The Malfunction Indicator Lamp (MIL) in the instrument cluster lights up if the malfunction is recognized for two subsequent starts.

EVAP canister system, checking for proper seal

Note. Secure all hose connections using hose clamps appropriate for the model type. Always replace seals and gaskets.

1. Connect diagnostic tester. See «CONNECT DIAGNOSTIC TESTER»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .
2. Start engine and let run at idle for at least 15 minutes.
3. In diagnostic function "33 - OBD", select "Mode 8: Tank leak test". See «MODE 8: TANK LEAK TEST»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-8-tank-leak-test) .
4. Select the "Test-ID 01: Tank leak test" and check specified value at idle. Specified value: Test OK

Note. If the accelerator pedal is depressed during the test, the test will be aborted. To repeat the tank leak test, switch ignition off and start engine again and let run at idle for at least 15 minutes.

If specified value is obtained

1. End diagnosis and switch ignition off.

If specified value is not obtained

Checking fuel supply and tank ventilation systems for leaks

1. Check whether fuel filler cap was completely closed for test.
2. Check whether seal of fuel filler cap is damaged or pinched. Replace if necessary.
3. Disconnect and seal connection hose. See item 6 of Leak detection pump (LDP) -V144- at EVAP canister.
4. Repeat function test.

If malfunction persists

1. Remove EVAP canister cover at bottom of spare wheel well.
2. Remove sealing pieces above ventilation lines.
3. Check connection pipes and hoses between Leak detection pump (LDP) -V144- and EVAP canister for proper seal. See «EVAP CANISTER/LEAK DETECTION SYSTEM - COMPONENT OVERVIEW»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__evap-canisterleak-detection-system-component) .
4. Repeat function test.

If malfunction persists

1. Remove luggage compartment lining.
2. Push forward the right backrest of rear seat, if necessary.

1. Remove left 1/3 backrest. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim in luggage compartment and dirt tray. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) and «DIRT TRAY, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .

Vehicles with All Wheel Drive (AWD)

1. Remove rear seat bench. See «SEATBENCH, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet__seatbench-removing-and-installing) (except Cabriolet), or for Cabriolet see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .

1. Check whether seals under connector flanges are OK and union nuts are properly tightened. Also check fuel line connections.
2. Visually check all wires and hose connections of fuel supply system and replace leaking lines, e.g.: Line from EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve (in engine compartment) Lines from EVAP canister to Leak Detection Pump (LDP) Line from fuel tank to Evaporative Emission (EVAP) canister (under cover for EVAP canister) Lines from EVAP system (under rear right wheel housing liner) Fuel lines to engine

Note. Leaks at lines and components of fuel tank system can sometimes be located using a nonflammable, environmentally sound engine leak detection spray (e.g. G 001 800 A1). Pressure of (max. 70 mbar) can be applied to the fuel system via the test connection (in engine compartment, right). Leaks can be determined using engine leak detection spray. When doing this, bubbles form at leaking areas.

1. Repeat function test.

If malfunction persists

1. Visually check components of fuel supply system and EVAP system. Fuel tank EVAP canister Leak Detection Pump (LDP) -V144- Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80

Note. Also check vacuum hose setup from engine compartment to leak detection pump for proper seal Because of shape or function of these components it is not always possible to find leaks by applying spray. It may be necessary to clamp off the relevant component using 3093 hose clamps and repeat leak detection diagnostic. If leak is no longer detected, the component that was clamped off is faulty. If clamp is placed directly on the diagnostic pump and a leak is still detected, then the diagnostic pump itself is leaking. Observe installation notes for connector flanges. See INSTALLING for FWD or INSTALLING for AWD.

After repair work, the following work steps must be performed in the mentioned sequence

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

1. VAG1526A hand multimeter
2. VAG1594A connector test kit
3. VAG1598/31 test box

1. Fuse for Evaporative Emission (EVAP) canister purge regulator valve -N80- OK See appropriate System Wiring Diagrams article.
2. Fuel Pump (FP) relay OK, checking. See «FUEL PUMP (FP) RELAY -J17- AND ACTIVATION, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-fp-relay-j17-and) .
3. Ignition switched off.

Note. Voltage for Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- is supplied via the fuel pump relay.

Work procedure

1. Disconnect electrical harness connector from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-.

Checking internal resistance

1. Connect multimeter at valve for resistance measurement. Specified value: 22...30 ohm

If specified value is not obtained.

1. Replace Evaporative Emission (EVAP) canister purge regulator valve -N80-.

If specified value is obtained

Checking voltage supply

1. Connect multimeter between terminal 1 and 2 for voltage measurement.
2. Operate starter briefly. Specified value: approx. battery voltage

If there is no voltage

1. Connect multimeter for voltage measurement as follows: EVAPORATIVE EMISSION CANISTER PURGE REGULATOR VALVE: TERMINAL 1 Harness connector Terminal Measure to 1 Engine Ground (GND)
2. Operate starter briefly. Specified value: approx. battery voltage
3. Switch ignition off.

If there is no voltage again

1. Check wire connection from harness connector terminal 1 to Fuel Pump (FP) Relay -J17- via fuse for open circuit according to wiring diagram. Specified value: Wire resistance max 1.5 ohm
2. If necessary, repair wire connection.

If voltage supply is OK

Scheme 214

1. Connect multimeter for voltage measurement as follows: EVAPORATIVE EMISSION CANISTER PURGE REGULATOR VALVE: TERMINAL 2 Harness connector Terminal Measure to 2 B+
2. Operate starter briefly. Specified value: approx. battery voltage
3. Switch ignition off.

If specified value is not obtained

Scheme 215

1. Connect test box to wiring harness of Engine Control Module (ECM). See «TEST BOX, CONNECTING FOR WIRING AND COMPONENT TEST»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) ; ECM is not connected.
2. Check the following wire connection for open circuit according to wiring diagram: EVAPORATIVE EMISSION CANISTER PURGE REGULATOR VALVE: TERMINAL 2 & SOCKET 64 Harness connector Terminal Test box Socket 2 64 Specified value: Wire resistance max 1.5 ohm
3. Also check the wire for short circuit to B+ and Ground (GND). Specified value: INFINITY ohm (no continuity)
4. If necessary, repair wire connection.

If no malfunctions are found in wires

1. Replace Engine Control Module (ECM).

After repair work, the following work steps must be performed in the mentioned sequence

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

1. VAG1526A hand multimeter
2. VAG1594A connector test kit
3. VAG1598/31 test box

1. Fuse for Leak Detection Pump (LDP) -V144- OK See appropriate System Wiring Diagrams article.
2. Fuel Pump (FP) relay OK, checking. See «FUEL PUMP (FP) RELAY -J17- AND ACTIVATION, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-18l-5v-turbo-amb__fuel-pump-fp-relay-j17-and) .
3. Ignition switched off.

Note. Voltage is supplied to Leak detection pump (LDP) -V144- via the Fuel Pump (FP) relay.

1. Remove left rear wheel.
2. Remove rear left wheelhouse liner.

See REAR WHEEL HOUSING LINER, ASSEMBLY OVERVIEW (except Cabriolet), or for Cabriolet see REAR WHEEL HOUSING LINER, ASSEMBLY OVERVIEW .

1. Release and disconnect harness connector -3-.

1. Connect multimeter for resistance measurement as follows.

LEAK DETECTION PUMP TERMINAL RESISTANCE

If specified values are not obtained

1. Replace Leak Detection Pump (LDP) -V144-. See item 11 .

If specified values are obtained

Scheme 216

1. Connect multimeter for voltage measurement as follows: LEAK DETECTION PUMP: TERMINAL 3 Harness connector Terminal Measure to 3 Engine Ground (GND)
2. Operate starter briefly. Specified value: approx. battery voltage
3. Switch ignition off.

If specified value is not obtained

1. Check wire connection from harness connector terminal 3 to Fuel Pump (FP) Relay -J17- via fuse for open circuit according to wiring diagram. Specified value: Wire resistance max 1.5 ohm
2. If necessary, repair wire connection.

If voltage supply is OK

Scheme 217

1. Connect test box to wiring harness of Engine Control Module (ECM). See «TEST BOX, CONNECTING FOR WIRING AND COMPONENT TEST»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) ; ECM is not connected.
2. Check the following wire connections for open circuit according to wiring diagram: LEAK DETECTION PUMP: TERMINAL 1, 2 & SOCKET 80, 25 Harness connector Terminal Test box Socket 1 80 2 25 Specified value: Wire resistance max 1.5 ohm
3. Also check wires for short circuit to each other as well as to B+ and Ground (GND). Specified value: INFINITY ohm (no continuity)
4. If necessary, repair wire connection.

If no malfunctions are found in wires

1. Replace Engine Control Module (ECM).

After repair work, the following work steps must be performed in the mentioned sequence

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off.

Function of E-Gas system

For E-Gas, the throttle valve is not operated by a cable from the accelerator pedal. There is no mechanical connection between the accelerator pedal and the throttle valve.

The position of the accelerator pedal is communicated to the Engine Control Module (ECM) via two sensors for accelerator pedal position (variable resistances; stored in one housing) that are connected with the accelerator pedal.

The accelerator pedal position (driver's intention) is a main input unit for the ECM.

Operation of the throttle valve occurs via an electric motor (throttle valve actuator) in the throttle valve control module. This is true across the entire engine speed and engine load spectrum.

The throttle valve is operated by the throttle valve actuator according to the instructions of the ECM.

With ignition switched on and engine off, the ECM activates the throttle valve actuator precisely according to the sensor for accelerator pedal position. This means, if the accelerator pedal is depressed half way, the throttle valve actuator opens the throttle valve to the same degree; i.e. throttle valve would be opened half way.

With engine running (under load), the ECM can open or close the throttle valve independently of the sensor for accelerator pedal position.

This means, for example, that the throttle valve could be fully opened even though the accelerator pedal has only been depressed half way. This has the advantage of preventing torque losses at the throttle valve.

In addition to this, it results in significantly better values relative to emissions and consumption under certain load conditions.

The required engine torque can be achieved by the Engine Control Module (ECM) via the optimal combination of throttle valve diameter and boost pressure.

It would be incorrect to think that "E-Gas" consists of only one or two components. E-Gas is much more of a system containing all components that contribute to recognizing, controlling and monitoring the position of the throttle valve, e.g. sensor for accelerator pedal position, throttle valve control module, EPC warning lamp, Engine Control Module (ECM).

Accelerator linkage, servicing

Note. The following list refers to see scheme 165.

1. Accelerator pedal module with Throttle Position (TP) sensor -G79- and sender -2- for accelerator pedal position -G185- Throttle Position (TP) Sensors -G79- and -G185-, checking. See «THROTTLE POSITION (TP) SENSOR, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb) . Removing and installing. See «ACCELERATOR PEDAL MODULE WITH THROTTLE POSITION (TP) SENSORS, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__accelerator-pedal-module-with-throttle-position) .
2. 10 N.m
3. 6-pin harness connector
4. 10 N.m

Accelerator pedal module with Throttle Position (TP) sensors, removing and installing

1. Remove driver-side storage compartment.

See DRIVER-SIDE STORAGE COMPARTMENT (WITH AND WITHOUT KNEE BOLSTER), ASSEMBLY OVERVIEW (except Cabriolet), or for Cabriolet see DRIVER'S STORAGE COMPARTMENT (VEHICLES WITH AND WITHOUT KNEE BOLSTER), ASSEMBLY OVERVIEW .

1. Disconnect 6-pin harness connector -2-.
2. Remove bolts -1- and -3-.
3. Remove accelerator pedal module.

Installation is the reverse of removal, noting the following

1. In a vehicle with automatic transmission, the kickdown function must be adapted when accelerator pedal module is replaced: To do so, switch on ignition and press accelerator pedal all the way down past the kickdown point and hold in position for at least 20 seconds.
2. Switch ignition off. Engine Control Module (ECM) now requires approx. 3 seconds to store the learned value. At this time, the ignition must not be switched on again

Tightening torque

TIGHTENING TORQUES: ACCELERATOR PEDAL MODULE

1. VAG1526A hand multimeter
2. VAG1594A connector test kit
3. VAG1598/31 test box

Test requirement

1. Fuses for engine electronics OK

See appropriate System Wiring Diagrams article.

Both the Throttle Position (TP) sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing.

1. Remove driver-side storage compartment.

See DRIVER-SIDE STORAGE COMPARTMENT (WITH AND WITHOUT KNEE BOLSTER), ASSEMBLY OVERVIEW (except Cabriolet), or for Cabriolet see DRIVER'S STORAGE COMPARTMENT (VEHICLES WITH AND WITHOUT KNEE BOLSTER), ASSEMBLY OVERVIEW .

1. Disconnect electrical harness connector -2-.

Scheme 218

1. Switch ignition on.
2. Connect multimeter for voltage measurement as follows. THROTTLE POSITION SENSOR TERMINAL VOLTAGE Harness connector Terminal Specified value 1 + Ground (GND) about 5 V 1 + 5 about 5 V 2 + Ground (GND) about 5 V 2 + 3 about 5 V
3. Switch ignition off.

If specified values are not obtained

Scheme 219

1. Connect test box to wiring harness of Engine Control Module (ECM). See «TEST BOX, CONNECTING FOR WIRING AND COMPONENT TEST»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) ; ECM is not connected.
2. Check the following wire connections for open circuit according to wiring diagram: THROTTLE POSITION SENSOR: TERMINALS & SOCKETS Harness connector Terminal Test box Socket 1 72 2 73 3 36 4 35 5 33 6 34 Specified value: Wire resistance max 1.5 ohm
3. Also check wires for short circuit to each other, to B+ and Ground (GND). Specified value: INFINITY ohm (no continuity)
4. If necessary, repair wire connection.

If no malfunction is detected in the wiring and if the voltage supply was OK

1. Replace accelerator pedal module. See «ACCELERATOR PEDAL MODULE WITH THROTTLE POSITION (TP) SENSORS, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply-generic-scan-tool-18l-5v-turbo-amb__accelerator-pedal-module-with-throttle-position) .

After repair work, the following work steps must be performed in the mentioned sequence

1. Check DTC memory. See «MODE 3: CHECK DTC MEMORY»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-3-check-dtc-memory) .
2. If necessary, erase DTC memory. See «MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb__mode-4-reseterase-diagnostic-data) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a4/b6-2000-2006/remont/testing-diagnostics/#engine-controls-on-board-diagnostic-obd-generic-scan-tool-18l-5v-turbo-amb) .

1. End diagnosis and switch ignition off

See also:
• SYSTEM PRESSURE AND RESIDUAL PRESSURE, CHECKING
• BATTERY DISCONNECT PRECAUTIONS
• LEFT 1/3 BACKREST, REMOVING AND INSTALLING
• SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW
• DIRT TRAY, ASSEMBLY OVERVIEW
• FUEL SYSTEM, BLEEDING
• MODE 3: CHECK DTC MEMORY
• MODE 4: RESET/ERASE DIAGNOSTIC DATA
• READINESS CODE, GENERATING
• FUEL PUMP (FP) RELAY -J17- AND ACTIVATION, CHECKING
• CHECKING FUEL PRESSURE REGULATOR -- VEHICLES WITH FRONT-WHEEL DRIVE
• SEATBENCH, REMOVING AND INSTALLING
• REAR SEAT BENCH, ASSEMBLY OVERVIEW
• MODE 8: TANK LEAK TEST
• REAR WHEEL HOUSING LINER, ASSEMBLY OVERVIEW
• REAR WHEEL HOUSING LINER, ASSEMBLY OVERVIEW
• DRIVER-SIDE STORAGE COMPARTMENT (WITH AND WITHOUT KNEE BOLSTER), ASSEMBLY OVERVIEW
• SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY SYSTEM
• RULES OF CLEANLINESS
• EMPTY FUEL TANK
• EMPTY FUEL TANK
• INSTALLATION POSITION OF GROUND (GND) CONNECTION
• FUEL PUMP, REMOVING AND INSTALLING
• RELEASING HARNESS CONNECTOR
• INSTALLING
• REMOVING AND INSTALLING FUEL PUMP
• EVAP CANISTER, REMOVING AND INSTALLING
• COMPONENT LOCATION OF T-PIECE
• EVAP CANISTER/LEAK DETECTION SYSTEM - COMPONENT OVERVIEW
• ACCELERATOR PEDAL MODULE WITH THROTTLE POSITION (TP) SENSORS, REMOVING AND INSTALLING