Fuel Supply Audi A4 B6

General repair notes

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

Safety precautions

See Caution (at the beginning of FUEL SUPPLY SYSTEM, SERVICING GUIDELINES ) before beginning repairs on the electrical system .

Perform the following steps before starting to work on the fuel supply system

1. With ignition switched off, disconnect ground strap from battery.
2. Open fuel filler cap briefly, then close it again.

When removing and installing components from a full or partly full fuel tank, note the following

When removing and installing fuel tank, note the following

Rules for cleanliness

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

1. Thoroughly clean all unions and the adjacent areas before disconnecting.
2. Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
3. Carefully cover opened components or seal, if the repair cannot be carried out immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (e.g. in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Note. Secure all hose connections with the correct hose clamps (same as original equipment) See Parts Catalog Hose clip pliers VAG 1921 are recommended when installing spring-type clamps. Always replace seals and gaskets when assembling.

Fuel tank with attachments, component overview

The following list pertains to (Scheme 1).

Note. The illustration shows fuel system for vehicles with 6-cyl. engine.

1. Fuel supply line From fuel filter To engine Do not kink Press release tab on connection piece to disconnect
2. Fuel return line From engine Do not kink Press release tab on connection piece to disconnect Clip onto fuel tank
3. Ventilation line To EVAP canister Do not kink Press release tab on connection piece to disconnect Clip onto fuel tank
4. Electrical harness connector Fuel Tank Lock Switch -F314- Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
5. 23 Nm Secures fuel filler neck and ground connection -Item 11
6. Overflow hose Engage in wheel housing liner
7. Rubber cup
8. Retaining ring
9. Seal Always replace if damaged
10. Filler cap
11. Ground connection To eliminate electrostatic charge Position/test procedure, see «INSTALLATION POSITION OF GROUND CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__installation-position-of-ground-connection) Make sure that connector is seated properly and secure wire with fastening bolt for fuel filler neck -Item 5 - 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 ohms
12. Ventilation line
13. Ventilation line From gravity valve to EVAP canister To remove, press release ring on EVAP canister
14. Ventilation line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clip to fuel tank
15. Fuel tank Removing and installing, see «FUEL TANK WITH ATTACHMENTS, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
16. Heat shield For fuel tank
17. 2 Nm
18. Heat shield For fuel tank
19. 2 Nm
20. Spreader clip
21. Securing strap Note differing length
22. 23 Nm

Installation position of ground connection

1. Route ground connection as shown in illustration.
2. Hook ground connection contact -1- into mounting hole on fuel tank -4-.
3. Make sure that ground connection connector -3- is properly seated on metal ring -2- on fuel filler neck.

1. Specification: approx. 0 ohms.

Special tools and equipment

1. VAS 5190

Work sequence

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system

1. With ignition switched off disconnect battery ground strap.

Scheme 1

Scheme 2

1. Detach tapered adapter -2- from shaft end -1- of VAS 5190.
2. Make a mark -arrow- on hose at distance a = 1465 mm from end of drain hose using insulating tape.
3. Remove filler cap from fuel tank filler neck.
4. Fit shaft end -1- of fuel extractor VAS 5190 onto fuel tank filler neck.
5. Push drain hose into fuel tank until marking on drain 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 on drain hose at distance a = 1400 mm from end of drain hose using insulating tape. The drain hose is fitted properly when marking on drain hose -arrow- coincides with rim of filler neck. If the hose does not go in easily, lubricate lightly with engine oil. Do not use silicone lubricant.
6. Drain tank as far as possible via fuel filler neck.
7. Carefully pull out drain hose.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

1. Observe safety precautions after connecting the battery.

1. VAG 1383 A and VAG 1359/2

Removing

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. Drain fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.

Sedan

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

Avant

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 3

1. Detach cover for flange -arrows-.
2. Release and remove electrical harness connector -1-.
3. Disconnect electrical harness connector -2-.

Vehicles with hose connection

1. Remove ventilation line -1-.

Vehicles with plug-in coupling

1. Disconnect ventilation line -1-. To do so, press unlocking ring -2- approx. 2mm in direction of arrow -A- and disconnect ventilation line -arrow B-.

All models

1. Remove right rear wheel.
2. Remove right rear wheel housing liner: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
3. Clean area around tank filler neck.
4. Open fuel filler flap, pry out tensioning ring (arrow) in rubber top (around filler neck). NOTE: Do not remove filler cap.
5. Press rubber cup through to the inside.
6. Remove rear section of exhaust system: For 1.8L Turbo engines, see «EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#engine-controls-turbocharger-exhaust-system-emission-controls-18l-5v-turbo-amb__exhaust-system-components-removing-and-installing) . For 3.0L V6 engines, see «EXHAUST SYSTEM, SERVICING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-servicing) . CAUTION: Secure vehicle against tipping over before LOOSENING the subframe bolts (e.g. Load trunk compartment with approx. 50 kg).
7. Remove rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear)
8. Remove floor panel covers -1- and -2-.

Fuel system with return line

1. Disconnect fuel supply hose -1- from fuel filter and catch escaping fuel.
2. Disconnect return hose -3- and ventilation line -2- at connection.

Fuel system without return line

1. Disconnect fuel supply hose -1- from fuel filter (press release button) and catch escaping fuel.
2. Disconnect ventilation line -2- (press release button).

Scheme 4

1. Disconnect ventilation line -2- from fuel filler neck.
2. Unscrew bolt -1- from tank filler neck.
3. Unscrew EVAP canister cover at bottom of spare tire well (arrows).
4. Remove ventilation lines -1- and -2-. To remove, press release ring -3- in direction of arrow -A- and pull off ventilation line -B-.
5. Unclip ventilation lines at top from bracket (arrow).
6. Position engine/transmission hoist VAG 1383 A below vehicle to support tank. WARNING: The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.
7. Take out bolts -1 through 7-.
8. Lower fuel tank with VAG 1383 A.

Installing

Install in reverse sequence; note the following points

Note. Secure all hose connections with the correct hose clamps (same as original equipment)

See Parts Catalog

1. Check that supply pipe, return pipe and ventilation line are clipped onto fuel tank -arrows-.
2. Check the ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.
3. Check position of ground connection: Make sure connector -3- is seated properly on metal ring -2-. The contact tab -1- must be hooked onto the fuel tank -4-.
4. Position fuel tank on underside of vehicle using engine/transmission jack VAG 1383 A.
5. Secure fuel tank by first tightening bolts at points -2- and -5-, then at the remaining points (23 Nm).

1. Specification: approx. 0 ohms

1. Install rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear)
2. Install rear section of exhaust system: For 1.8L Turbo engines, see «EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTA»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#engine-controls-turbocharger-exhaust-system-emission-controls-18l-5v-turbo-amb__exhaust-system-components-removing-and-installing) . For 3.0L V6 engines, see «EXHAUST SYSTEM, SERVICING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-servicing) .
3. Install rear right wheel housing liner and tighten fastening bolt for fuel filler neck

For Cabriolet models, see WHEEL HOUSING LINER . For models other than Cabriolet, see WHEEL HOUSING LINER .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

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

TIGHTENING TORQUES: FUEL TANK (FRONT-WHEEL DRIVE, VEHICLES UP TO 06.2003)

Fuel delivery unit and fuel gauge sender, component overview

The following list pertains to (Scheme 23).

Note. The illustration shows fuel delivery unit for vehicles with 6-cyl engine.

1. Sender for fuel gauge -G- Testing resistance, see «SENDER FOR FUEL GAUGE -G-, TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «FUEL GAUGE SENDER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
2. Fuel delivery unit Testing fuel pump (electrical test), see «FUEL PUMP, TESTING (ELECTRICAL TEST)»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Checking delivery rate, from «FUEL PUMP DELIVERY RATE, CHECKING - VEHICLES WITH 4-CYL. TURBO ENGINE»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Checking holding pressure: For 1.8L Turbo engine, see «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__system-pressure-fuel-pressure-regulator-and). For 3.0L V6 engine, see «FUEL PRESSURE REGULATOR AND HOLDING PRESSURE (VEHICLES UP TO 06.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__fuel-pressure-regulator-and-holding-pressure). Removing and installing, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
3. Seal Always replace When installing, fit seal (dry) in opening in fuel tank
4. Fuel return pipe Mark pipe before disconnecting 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 Clip onto fuel tank
5. Fuel supply pipe Mark pipe before disconnecting 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 Clip onto fuel tank
6. Electrical connector For fuel pump and Sender for fuel gauge -G- Releasing => (Scheme 24)
7. Union nut, 80 Nm Remove and install using wrench 3217
8. Suction jet pipe To remove, press release button on connection piece
9. Suction jet pump

Releasing connector

1. To disconnect multi-pin connector at fuel delivery unit, first release retaining catch. This can be done manually or by using a small screwdriver -arrow-.

1. VAG 1348/3A with VAG 1348/3-2
2. VAG 1526 A
3. VAG 1594 A

Requirements for test

1. Battery voltage not less than 12.7 V
2. Fuse in fuse holder -S228- OK (plug-in position No. 28)
3. Fuel pump relay (arrow) OK (located at plug-in position No. 1 in nine-way relay carrier behind storage compartment on driver's side)
4. Fuel filter OK
5. Ignition switched off

Test sequence

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- off plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A with adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of fuse in fuse holder -S228- (plug-in position No. 28).
4. Connect clamp to vehicle battery (+).
5. Press remote control switch. Pump should start running (audible when standing close to fuel tank).

Note. The fuel pump runs very quietly. Where possible, avoid noisy surroundings for this test.

If pump does not start running

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

1. Detach cover for flange -arrows-.
2. Disengage and remove electrical harness connector -1-.
3. Connect multimeter (voltage range) between contacts 1 and 4 of connector.
4. Press remote control switch. Specification: approx. battery voltage If the specified value is not reached
5. Repair open circuit in wiring according to wiring diagram.

If the specification is obtained, even though the fuel pump did not run

1. Remove fuel delivery unit, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .
2. Check that electrical wires between flange and fuel pump are connected and test for continuity.

If no fault is detected in the wires, fuel pump is malfunctioning. Replace fuel delivery unit.

1. Installing fuel delivery unit, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

1. VAG 1318/17-1 adapter
2. VAG 1348/3A and VAG 1348/3-2
3. Fuel-resistant measuring container

1. Battery voltage not less than 12.7 V
2. Fuel filter OK
3. Fuel tank at least 1/4 full.
4. Fuel pressure regulator OK, check: For 1.8L engine, see «CHECKING FUEL PRESSURE REGULATOR -- VEHICLES»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__checking-fuel-pressure-regulator-vehicles) .
5. Ignition switched off.

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- out of plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A together with adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28).
4. Connect clamp to vehicle battery positive (+).
5. Remove filler cap from fuel tank filler neck.

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 5

Scheme 6

1. Detach cover for flange -arrows-. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
2. Disconnect fuel return pipe -2- (press release button). NOTE: The fuel supply pipe -1- remains connected.
3. Connect VAG1318/17-1 adapter to the disconnected fuel return line and hold it into a measuring container.
4. Operate remote control for 15 seconds (keep button pressed).
5. Compare the quantity of fuel delivered with specification. *) Minimum delivery cm 3 /15 seconds **) Voltage at fuel pump with engine stationary and pump running (approx. 2 volts less than battery voltage).
6. Connect fuel return hose.

1. VAG 1348/3A and VAG 1348/3-2
2. Fuel-resistant measuring container

1. Battery voltage not less than 12.7 V
2. Fuel filter OK
3. Fuel tank at least 1/4 full.
4. Fuel pressure regulator OK, check: For 3.0L engine, see «FUEL PRESSURE REGULATOR AND HOLDING PRESSURE (VEHICLES UP TO 06.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__fuel-pressure-regulator-and-holding-pressure) .
5. Ignition switched off

Scheme 7

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- out of plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A together with adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28).
4. Connect clamp to vehicle battery positive (+).
5. Remove filler cap from fuel tank filler neck. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
6. Disconnect fuel return hose at connection on fuel distribution pipe (fuel rail).
7. Connect extension hose -arrow- to fuel distribution pipe and hold end of hose in measuring container.
8. Operate remote control for 15 seconds (keep button pressed).
9. Compare the quantity of fuel delivered with specification. *) Minimum delivery cm 3 /15 seconds **) Voltage at fuel pump with engine stationary and pump running (approx. 2 volts less than battery voltage).
10. Connect fuel return hose.

Note. Secure all hose connections with the correct hose clamps (same as original equipment)

See Parts Catalog

1. Union nut wrench 3217

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Drain fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system

1. With ignition switched off, disconnect battery ground strap.

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 8

1. Detach cover for flange -arrows-.
2. Disengage and remove electrical harness connector -1-.
3. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
4. Mark fuel supply pipe -1- and fuel return pipe -2- and disconnect (press release tabs).

Scheme 9

1. In addition, disconnect breather line to fuel filter at locking flange. WARNING: The fuel tank must not be more than 3/4 full when removing the fuel delivery unit.
2. Unscrew union nut using wrench 3217.
3. Carefully pull fuel delivery unit a short distance out of fuel tank opening together with seal.
4. Move flange slightly to one side with fuel delivery unit still located in fuel tank.
5. Reach into gap between flange and opening in fuel tank and release suction jet pump -1-. NOTE: The fuel tank is shown in partial section.
6. Lift suction jet pump -1- with suction jet pipe -2- connected.
7. Disconnect suction jet pipe from suction jet pump (press release tab).
8. Remove suction jet pump.
9. Take out fuel delivery unit.

Install in reverse sequence; note the following points

1. Attach suction jet pipe -2- to suction jet pump connection -1-.
2. Fit fuel delivery unit in fuel tank.
3. Clip suction jet pump -1- onto fuel delivery unit. To do this reach into gap between flange and opening in fuel tank. The suction jet pump should engage with an audible click.
4. Fit new seal for flange in fuel tank opening (seal should be dry).
5. Note installation position of fuel delivery unit: Marking on flange -2- must coincide with marking on fuel tank -1-.
6. Tighten union nut on flange to 80 Nm.
7. Install fuel supply pipe -1- and fuel return pipe -2- (as marked on removal).

Vehicles with 4-cylinder Turbo engine

1. In addition, install breather line to fuel filter at locking flange.

1. Connect all electrical harness connectors.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

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

TIGHTENING TORQUES: FUEL DELIVERY UNIT (FRONT-WHEEL DRIVE, VEHICLES UP TO 06.2003)

1. VAG 1526 A
2. VAG 1594 A

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 10

1. Detach cover for flange -arrows-.
2. Disengage and remove electrical harness connector -1-.
3. Connect multimeter (resistance range) between contacts 2 and 3. FUEL GAUGE SENDER RESISTANCE SPECIFICATIONS, SENDER INSTALLED - FRONT-WHEEL DRIVE, VEHICLES UP TO 06.2003 Sender installed Sender at lower impact Sender at upper impact Sender for fuel gauge -G- 300 - 310 ohm 53.5 - 59 ohm
4. If the resistance is 0 ohm, there is a short circuit. If the resistance is infinite ohms, there is an open circuit in the wiring.

Note. To check resistance values for "tank full" or "tank empty", the Fuel Pump (FP) must be removed, see FUEL DELIVERY UNIT, REMOVING AND INSTALLING , and the sensor float must be placed in the upper or lower end position.

When the fuel gauge sender is removed, the arm of the float will travel further and the specifications are

FUEL GAUGE SENDER RESISTANCE SPECIFICATIONS, SENDER REMOVED - FRONT-WHEEL DRIVE, VEHICLES UP TO 06.2003

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. Remove fuel delivery unit. See «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .
2. Release connectors -1- and -2- and disconnect.
3. Carefully lift retaining lugs -3- and -4- using a screwdriver and pull fuel gauge sender off towards bottom -arrow-.

Install in reverse sequence; note the following points

1. Insert fuel gauge sender into the guides on fuel delivery unit and press upward until it clicks into place.
2. Connect connector tabs of wiring and check they have engaged properly.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

1. Install fuel delivery unit. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)

Fuel Tank Lock Switch -F314

The Fuel Tank Lock Switch -F314- consists of a reed contact on the fuel filler tube and a fuel filler cap with an embedded magnet.

If the fuel filler cap is not fully bolted on, the reed contact switches and triggers an indication on the display in instrument cluster.

Scheme 11

1. Check the following items in order with a lighted display: Fuel filler cap is installed and threaded in tightly Proper fuel filler cap (recognized by: threads are colored gray) Switch (arrow) is fully inserted at fuel filler tube Electrical malfunction in switch. Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Faulty wiring connection to instrument cluster (check according to wiring diagram)

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

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

1. Remove cover for locking flange (arrows).
2. Disconnect electrical harness connector -2-.
3. Connect multimeter between terminals 1 and 2 for resistance measurement.

FUEL TANK LOCK SWITCH RESISTANCE SPECIFICATIONS - FRONT-WHEEL DRIVE, VEHICLES UP TO 06.2003

If specified values are not obtained

1. Right-rear wheelhousing liner, removing: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
2. Replace Fuel Tank Lock Switch -F314- (arrow), to do this, unclip switch and electrical wire to fuel filler tube and reclip them afterward.

Note. Secure all hose connections with the correct hose clamps (same as original equipment) See Parts Catalog Hose clip pliers VAG 1921 are recommended when installing spring-type clamps. Always replace seals and gaskets when assembling.

The following list pertains to (Scheme 66).

1. Fuel supply line From fuel filter To engine Do not kink Press release tab on connection piece to disconnect
2. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Do not kink Press release tab on connection piece to disconnect Clip onto fuel tank
3. Electrical harness connector for Fuel Tank Lock Switch -F314- Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
4. 2 Nm
5. Heat shield for fuel filler neck
6. 23 Nm Secures fuel filler neck and ground connection -Item 12
7. Overflow hose Engage in wheel housing liner
8. Rubber cup
9. Retaining ring
10. Seal Always replace if damaged
11. Filler cap
12. Ground connection To eliminate electrostatic charge Position/test procedure, see «INSTALLATION POSITION OF GROUND CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) . Make sure that connector is seated properly and secure wire with fastening bolt for fuel filler neck -Item 6- 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 ohm
13. Ventilation line
14. Ventilation line From gravity valve to EVAP canister To remove, press release ring on EVAP canister
15. Ventilation line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clip to fuel tank
16. Fuel tank Removing and installing, see «FUEL TANK WITH ATTACHMENTS, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
17. Heat shield For fuel tank
18. 2 Nm
19. Heat shield For fuel tank
20. 2 Nm
21. Spreader clip
22. Securing strap Note differing length
23. 23 Nm

1. Route ground connection as shown in illustration.
2. First, hook ground connection contact -1- into mounting hole on fuel tank -5- and then press in spacer sleeve -2-.
3. Make sure that ground connection connector -4- is properly seated on metal ring -3- on fuel filler neck.

1. Specification: approx. 0 ohms.

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. VAS 5190

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system

Scheme 12

Scheme 13

1. With ignition switched off disconnect battery ground strap. WARNING: Secure ground wire of VAS 5190 to a bare metal part on the body.
2. Detach tapered adapter -2- from shaft end -1- of VAS 5190.
3. Make a mark -arrow- on hose at distance a = 1465 mm from end of drain hose using insulating tape.
4. Remove filler cap from fuel tank filler neck.
5. Fit shaft end -1- of fuel extractor VAS 5190 onto fuel tank filler neck.
6. Push drain hose into fuel tank until marking on drain 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 on drain hose at distance a = 1400 mm from end of drain hose using insulating tape. The drain hose is fitted properly when marking on drain hose -arrow- coincides with rim of filler neck. If the hose does not go in easily, lubricate lightly with engine oil. Do not use silicone lubricant.
7. Drain tank as far as possible via fuel filler neck.
8. Carefully pull out drain hose. See Caution (at the beginning of «FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES AS OF 07.2003»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) ) for connecting Telematics battery
9. Observe safety precautions after connecting the battery.

1. VAG 1383 A and VAG 1359/2

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. Drain fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 14

1. Detach cover for flange -arrows-.
2. Release and remove electrical harness connector -1-.
3. Disconnect electrical harness connector -2-.
4. Remove ventilation line -1-. For this, press release ring -2- approx. 2 mm in direction of arrow -A- and disconnect ventilation line -arrow B-.
5. Remove right rear wheel.
6. Remove right rear wheel housing liner: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
7. Clean area around tank filler neck.
8. Open fuel filler flap, pry out tensioning ring (arrow) in rubber top (around filler neck). NOTE: Do not remove filler cap.
9. Press rubber cup through to the inside.
10. Remove rear section of exhaust system: For 1.8L Turbo engines, see «EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#engine-controls-turbocharger-exhaust-system-emission-controls-18l-5v-turbo-amb__exhaust-system-components-removing-and-installing) . For 3.0L V6 engines, see «EXHAUST SYSTEM, SERVICING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-servicing) . CAUTION: Secure vehicle against tipping over before LOOSENING the subframe bolts (e.g. Load trunk compartment with approx. 50 kg).
11. Remove rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear)
12. Remove floor panel covers -1- and -2-. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
13. Disconnect fuel supply hose -1- from fuel filter (press release button) and catch escaping fuel.
14. Disconnect ventilation line -2- (press release button).
15. Disconnect ventilation line -2- from fuel filler neck (press release tabs).
16. Unscrew bolt -1- from tank filler neck.
17. Unscrew EVAP canister cover at bottom of spare tire well (arrows).
18. Remove ventilation lines -1- and -2-. To remove, press release ring -3- in direction of arrow -A- and pull off ventilation line -B-.
19. Unclip ventilation lines at top from bracket (arrow).
20. Position engine/transmission hoist VAG 1383 A below vehicle to support tank. WARNING: The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.
21. Take out bolts -1 through 7-.
22. Lower fuel tank with VAG 1383 A.

Install in reverse sequence; note the following points

Note. Secure all hose connections with the correct hose clamps (same as original equipment)

See Parts Catalog

Scheme 15

1. Check that supply pipe, return pipe, breather pipe and vent pipe are clipped onto fuel tank -arrows-.
2. Check the ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.
3. Check position of ground connection: Make sure connector -4- is connected securely on metal ring -3-. The contact tab -1- must be hooked onto the fuel tank -5- and secured via spacer sleeve -2-.
4. Position fuel tank on underside of vehicle using engine/transmission jack VAG 1383 A.
5. Secure fuel tank by first tightening bolts at points -2- and -5- then at the remaining points (23 Nm). CAUTION: 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 ohms
6. Install rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear)
7. Install rear section of exhaust system: For 1.8L Turbo engines, see «EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#engine-controls-turbocharger-exhaust-system-emission-controls-18l-5v-turbo-amb__exhaust-system-components-removing-and-installing) . For 3.0L V6 engines, see «EXHAUST SYSTEM, SERVICING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-servicing) .
8. Install rear right wheel housing liner and tighten fastening bolt for fuel filler neck

For Cabriolet models, see WHEEL HOUSING LINER . For models other than Cabriolet, see WHEEL HOUSING LINER .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery

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

TIGHTENING TORQUES: FUEL TANK (FRONT-WHEEL DRIVE, VEHICLES AS OF 07.2003)

The following list pertains to (Scheme 86).

1. Sender for fuel gauge -G- Testing resistance, see «SENDER FOR FUEL GAUGE -G-, TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «FUEL GAUGE SENDER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
2. Fuel delivery unit Testing fuel pump (electrical test), see «FUEL PUMP, TESTING (ELECTRICAL TEST)»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Checking delivery rate, see «FUEL PUMP DELIVERY RATE, CHECKING - VEHICLES WITH 4-CYL. TURBO ENGINE AND 6-CYL. ENGINE»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Checking holding pressure: For 1.8L Turbo, see «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__system-pressure-fuel-pressure-regulator-and) . For 3.0L V6, see «SYSTEM PRESSURE AND HOLDING PRESSURE (VEHICLES AS OF 07.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__system-pressure-and-holding-pressure-vehicles) . Removing and installing, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
3. Seal Always replace When installing, fit seal (dry) in opening in fuel tank
4. Fuel return pipe From fuel filter Mark pipe before disconnecting 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 Clip onto fuel tank
5. Fuel breather pipe From fuel pressure regulator in fuel filter Press release tab on connection piece to disconnect Do not kink Clip onto fuel tank
6. Fuel supply line To fuel filter Mark pipe before disconnecting 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 Clip onto fuel tank
7. Electrical harness connector For fuel pump and Sender for fuel gauge -G- Releasing, see «Releasing connector»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
8. Locking ring Remove and install using 3087 wrench Tighten to 145 Nm
9. Suction jet pipe To remove, press release button on connection piece
10. Suction jet pump

1. To disconnect multi-pin connector at fuel delivery unit, first release retaining catch. This can be done manually or by using a small screwdriver -arrow-.

1. VAG 1348/3A with VAG 1348/3-2
2. VAG 1526 A
3. VAG 1594 A

1. Battery voltage not less than 12.7 V
2. Fuse in fuse holder -S228- OK (plug-in position No. 28)
3. Fuel pump relay (arrow) OK (located at plug-in position No. 1 in nine-way relay carrier behind storage compartment on driver's side)
4. Fuel filter OK
5. Ignition switched off

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- off plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A with adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28).
4. Connect clamp to vehicle battery (+).
5. Press remote control switch. Pump should start running (audible when standing close to fuel tank).

Note. The fuel pump runs very quietly. Where possible, avoid noisy surroundings for this test.

If no running noise is audible

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

All vehicles

1. Detach cover for flange -arrows-.
2. Disengage and remove electrical harness connector -1-.
3. Connect multimeter (voltage range) between contacts 1 and 4 of connector.
4. Press remote control switch. Specification: approx. battery voltage

If specification is not reached

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

If the specification is obtained, even though the fuel pump did not run

1. Remove fuel delivery unit. See «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
2. Check that electrical wires between flange and fuel pump are connected and test for continuity.

If no fault is detected in the wires, fuel pump is malfunctioning. Replace fuel delivery unit.

1. Installing fuel delivery unit. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

1. V.A.G 1318/17-1 Adapter
2. VAG 1348/3A and VAG 1348/3-2
3. Fuel-resistant measuring container

1. Battery voltage not less than 12.7 V
2. Fuel filter OK
3. The fuel tank must be at least 1/4 full.
4. Fuel pressure regulator OK, checking: For 1.8L Turbo, see «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__system-pressure-fuel-pressure-regulator-and) . For 3.0L V6, see «SYSTEM PRESSURE AND HOLDING PRESSURE (VEHICLES AS OF 07.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__system-pressure-and-holding-pressure-vehicles) .
5. Ignition switched off

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- out of plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A together with adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28).
4. Connect clamp to vehicle battery positive (+).
5. Remove filler cap from fuel tank filler neck.

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 16

Scheme 17

1. Detach cover for flange -arrows-. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
2. Disconnect fuel return pipe -arrow- (press release tab). NOTE: The fuel supply pipe -1- remains connected.
3. Fit adapter V.A.G 1318/17-1 onto disconnected fuel return pipe and hold pipe in measuring container.
4. Operate remote control for 15 seconds (keep button pressed).
5. Compare the quantity of fuel delivered with specification. *)Minimum delivery cm3/15 seconds **)Voltage at fuel pump with engine stationary and pump running (approx. 2 volts less than battery voltage).
6. Connect fuel return hose.

1. Union nut wrench 3087

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules of cleanliness. See RULES FOR CLEANLINESS .

1. The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Drain fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system

1. With ignition switched off, disconnect battery ground strap.

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet)
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 18

Scheme 19

Scheme 20

1. Detach cover for flange -arrows-.
2. Disengage and remove electrical harness connector -1-.
3. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
4. Mark fuel supply pipe -1- and fuel return pipe -3- and disconnect (press release tab).
5. Disconnect breather pipe -2- (press release tab). WARNING: The fuel tank must not be more than 3/4 full when removing the fuel delivery unit.
6. Unscrew locking ring using wrench 3087.
7. Carefully pull fuel delivery unit a short distance out of fuel tank opening together with seal.
8. Move flange slightly to one side with fuel delivery unit still located in fuel tank.
9. Reach into gap between flange and opening in fuel tank and release suction jet pump -1-. NOTE: The fuel tank is shown in partial section.
10. Lift suction jet pump -1- with suction jet pipe -2- connected.
11. Disconnect suction jet pipe from suction jet pump (press release tab).
12. Remove suction jet pump.
13. Take out fuel delivery unit.

Install in reverse sequence; note the following points

Scheme 21

Scheme 22

1. Attach suction jet pipe -2- to suction jet pump connection -1-.
2. Fit fuel delivery unit in fuel tank.
3. Clip suction jet pump -1- onto fuel delivery unit. To do this reach into gap between flange and opening in fuel tank. The suction jet pump should engage with an audible click.
4. Fit new seal for flange in fuel tank opening (seal should be dry).
5. Note installation position of fuel delivery unit: Lug -2- at flange must be positioned between tabs -1- and -3- at fuel tank. NOTE: The arrow points in the direction of travel.
6. Tighten locking ring on flange to 145 Nm.
7. Install fuel supply pipe -1- and fuel return pipe -3- (as marked on removal).
8. Install breather pipe -2-.
9. Connect electrical harness connectors.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery .

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

TIGHTENING TORQUES: FUEL DELIVERY UNIT (FRONT-WHEEL DRIVE, VEHICLES AS OF 07.2003)

1. VAG 1526 A
2. VAG 1594 A

1. Detach trim in luggage compartment.
2. Fold down rear right seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 23

1. Detach cover for flange -arrows-.
2. Disengage and remove electrical harness connector -1-.
3. Connect multimeter (resistance range) between contacts 2 and 3. FUEL GAUGE SENDER RESISTANCE SPECIFICATIONS (SENDER INSTALLED) - FRONT-WHEEL DRIVE, VEHICLES AS OF 07.2003 Sender installed Sender at lower impact Sender at upper impact Sender for fuel gauge -G- 300-310 ohm 53.5 - 59 ohm
4. If the resistance is 0 ohm there is a short circuit. If the resistance is ohm there is an open circuit in the wiring.

Note. To check resistance values for "tank full" or "tank empty", the Fuel Pump (FP) must be removed. See FUEL DELIVERY UNIT, REMOVING AND INSTALLING , and the sensor float must be placed in the upper or lower end position.

When the fuel gauge sender is removed, the arm of the float will travel further and the specifications are

FUEL GAUGE SENDER RESISTANCE SPECIFICATIONS (SENDER REMOVED) - FRONT-WHEEL DRIVE, VEHICLES AS OF 07.2003

Observe safety precautions. See SAFETY PRECAUTIONS

Observe rules of cleanliness. See RULES FOR CLEANLINESS .

1. Remove fuel delivery unit. See «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .
2. Release connectors -1- and -2- and disconnect.
3. Carefully lift retaining lugs -3- and -4- using a screwdriver and pull fuel gauge sender off towards bottom -arrow-.

Install in reverse sequence; note the following points

1. Insert fuel gauge sender into the guides on fuel delivery unit and press upward until it clicks into place.
2. Connect connector tabs of wiring and check they have engaged properly.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (FRONT-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery

1. Install fuel delivery unit, see «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

The Fuel Tank Lock Switch -F314- consists of a reed contact on the fuel filler tube and a fuel filler cap with an embedded magnet.

If the fuel filler cap is not fully bolted on, the reed contact switches and triggers an indication on the display in instrument cluster.

Scheme 24

1. Check the following items in order with a lighted display: Fuel filler cap is installed and threaded in tightly Proper fuel filler cap (recognized by: threads are colored gray) Switch (arrow) is fully inserted at fuel filler tube Electrical malfunction in switch. Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Faulty wiring connection to instrument cluster (check according to wiring diagram)

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

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

1. Remove cover for locking flange (arrows).
2. Disconnect electrical harness connector -2-.
3. Connect multimeter between terminals 1 and 2 for resistance measurement.

FUEL TANK LOCK SWITCH RESISTANCE

If specified values are not obtained

1. Right-rear wheelhousing liner, removing: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
2. Replace Fuel Tank Lock Switch -F314- (arrow), to do this, unclip switch and electrical wire to fuel filler tube and reclip them afterward.

Note. Secure all hose connections with the correct hose clamps (same as original equipment) See Parts Catalog Hose clip pliers VAG 1921 are recommended when installing spring-type clamps. Always replace seals and gaskets when assembling.

The following list pertains to see scheme 125.

Note. A fuel system with return line is displayed in illustration.

1. Bracket For exhaust system
2. Carrier plate
3. Fuel supply line From fuel filter To engine Do not kink Press release tab on connection piece to disconnect
4. Ventilation line To EVAP canister Do not kink Press release tab on connection piece to disconnect Clip onto fuel tank
5. Fuel return line From engine Clip onto fuel tank
6. Electrical harness connector For Fuel Tank Lock Switch -F314- Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__electrical-test-for-fuel-tank-lock)
7. 2 Nm
8. Heat shield
9. 23 Nm Secures fuel filler neck and ground connection - Item 15
10. Overflow hose
11. Rubber cup
12. Retaining ring
13. Seal Always replace if damaged
14. Filler cap
15. Ground connection To eliminate electrostatic charge Position / test procedure, see «POSITION OF GROUND CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__position-of-ground-connection) Make sure that connector is seated properly and secure wire with fastening bolt for fuel filler neck -Item 9 - 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 ohm
16. Ventilation line
17. Spring clip
18. Ventilation line From gravity valve to EVAP canister To remove, press release ring on EVAP canister
19. Ventilation line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clip on to fuel tank
20. Fuel tank Removing and installing, see «FUEL TANK WITH ATTACHMENTS, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
21. Securing strap
22. Spreader clip
23. 23 Nm
24. Heat shield For fuel tank
25. 2 Nm
26. 23 Nm

Position of ground connection

1. Route ground connection as shown in illustration.
2. First hook ground connection contact -1- into mounting hole on fuel tank -4-.
3. Make sure that ground connection connector -3- is properly seated on metal ring -2- on fuel filler neck.

1. Specification: approx. 0 ohms.

1. Wrench for fuel tank sender unit 3087
2. VAS 5190

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system

1. With ignition switched off disconnect battery ground strap.

Scheme 25

Scheme 26

Scheme 27

1. Detach tapered adapter -2- from shaft end -1- of VAS 5190.
2. Make a mark -arrow- on hose at distance a = 1865 mm from end of drain hose using insulating tape.
3. Remove filler cap from fuel tank filler neck.
4. Fit shaft end -1- of fuel extractor VAS 5190 onto fuel tank filler neck.
5. Push drain hose into fuel tank until marking on drain 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 drain hose at distance a = 1800 mm from end of drain hose using insulating tape. The drain hose is fitted properly when marking on drain hose coincides with rim of filler neck. If the hose does not go in easily, lubricate lightly with engine oil. Do not use silicone lubricant.
6. Drain tank as far as possible via fuel filler neck.
7. Carefully pull out drain hose.
8. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
9. Detach cover for flange -arrows- (right side).
10. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
11. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
12. Disconnect fuel supply pipe -1- from locking flange (right side of vehicle).

Vehicles with 4-cylinder Turbo engine

1. In addition, disconnect breather pipe -2- to fuel filter from flange.

1. Unscrew locking ring using wrench for fuel tank sender unit 3087.
2. Remove flange and seal out of opening in fuel tank.
3. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
4. Insert drain hose to marking x = 800 mm through right opening in fuel tank and into left fuel chamber.
5. Draw off fuel from left chamber of fuel tank.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

1. Re-install flange (right side). See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) ; observe notes on procedure for connecting battery.

1. VAG 1383 A and VAG 1359/2

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. Drain fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system .

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.

1. Detach trim in luggage compartment.
2. Fold down right rear seat backrest if necessary.

1. Remove 1/3 backrest, left See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

1. Unscrew cover -arrows-.
2. Disconnect ventilation line -1- (press release tab).
3. Detach ventilation line -2-.
4. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
5. Detach cover for flange (left and right side) -arrows-.
6. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
7. Disconnect electrical harness connector -2-.
8. Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle).
9. Remove right-rear wheel.
10. Remove right-rear right wheel housing liner: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
11. Clean area around tank filler neck.
12. Pry out clamping ring -arrow-in rubber cup (on filler neck). NOTE: Do not remove filler cap.
13. Press rubber cup through to the inside.
14. Remove rear section of exhaust system: For 1.8L Turbo engines, see «EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#engine-controls-turbocharger-exhaust-system-emission-controls-18l-5v-turbo-amb__exhaust-system-components-removing-and-installing) . For 3.0L V6 engines, see «EXHAUST SYSTEM, SERVICING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-servicing) . For 4.2L V8, see «EXHAUST COMPONENTS, REMOVING AND INSTALLING»(ref-197062-S17437019812005101100000) .
15. Remove propshaft: See «DRIVESHAFT & UNIVERSAL JOINTS - 01V (AWD TRANSAXLE)»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle) . CAUTION: Secure vehicle against tipping over before LOOSENING the subframe bolts (e.g. load trunk compartment with approx. 50 kg).
16. Remove rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear)

Fuel system with return pipe

1. Disconnect fuel supply hose -1-from fuel filter and catch escaping fuel.
2. Disconnect return hose -3- and ventilation line -2- at connection.

Fuel system without return pipe

1. Disconnect fuel supply hose -1- from fuel filter (press release button) and catch escaping fuel.
2. Disconnect ventilation line -2- (press release button).

1. Disconnect ventilation lines -2- and -3- from fuel filler neck.
2. Remove bolt -1-for fuel filler neck.
3. Remove EVAP canister cover at bottom of spare tire well (arrows).
4. Disconnect ventilation lines -1- and -2-. To do so, press release ring -3- in direction of arrow -A- and pull off ventilation line (arrow -B-).
5. Unclip ventilation lines at top from bracket (arrow).
6. Detach heat shields -1- and -2-.
7. Detach handbrake cables from the retainers marked by arrows.
8. Position engine/transmission hoist VAG 1383 A below vehicle to support tank. WARNING: The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.
9. Take out bolts -1 through 10-.
10. Lower fuel tank with carrier plate.

Install in reverse sequence; note the following points

Note. Secure all hose connections using the correct type of hose clamps (as original equipment): See Parts Catalog

1. Check that supply hoses, return hoses and ventilation lines are clipped onto fuel tank.
2. Check the ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.
3. Check position of ground connection: Make sure connector -3- is seated properly on metal ring -2-. The contact tab -1- must be hooked onto the fuel tank -4-.
4. Position fuel tank with securing straps and carrier plate on underside of vehicle using engine/transmission jack VAG 1383 A.
5. Tighten bolts -1 through.10-for securing straps and carrier plate to 23 Nm.
6. Secure fuel filler neck (23 Nm). CAUTION: 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 ohms
7. Install rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear)
8. Install propshaft: See «DRIVESHAFT & UNIVERSAL JOINTS - 01V (AWD TRANSAXLE)»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle) .
9. Install rear part of exhaust system

For 1.8L Turbo engines, see EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION . For 3.0L V6 engines, see EXHAUST SYSTEM, SERVICING . For 4.2L V8, see EXHAUST COMPONENTS, REMOVING AND INSTALLING .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

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

TIGHTENING TORQUES: FUEL TANK (ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003)

Part I

The following list pertains to see scheme 155.

1. Sender for fuel gauge -G- Clipped onto reservoir housing in fuel tank Checking resistance, see «SENDER FOR FUEL GAUGE -G-, TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «SENDER FOR FUEL GAUGE -G-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
2. Fuel delivery unit Different versions are available; for correct version: See Parts Catalog Can only be replaced together with flange Checking fuel pump (electrical test), see «FUEL PUMP, TESTING (ELECTRICAL TEST)»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Checking delivery rate, see «FUEL PUMP DELIVERY RATE, CHECKING - VEHICLES WITH 4-CYL. TURBO ENGINE»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Checking holding pressure: For 1.8L Turbo engine, see «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__system-pressure-fuel-pressure-regulator-and) . For 3.0L V6 engine, see «FUEL PRESSURE REGULATOR AND HOLDING PRESSURE (VEHICLES UP TO 06.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__fuel-pressure-regulator-and-holding-pressure) . For 4.2L V8, go to «FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, CHECKING»(ref-213322-S07247353192005122900000) . Removing and installing, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
3. Electrical connector For fuel pump and Sender for fuel gauge -G- Releasing, see «Releasing connector»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
4. Flange For fuel delivery unit Cannot be replaced separately Installation position, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
5. Seal Replace When installing, fit seal (dry) in fuel tank opening
6. Locking ring Remove and install using wrench 3087 Tighten to 145 Nm
7. Fuel supply line To fuel filter Press release tab on connection piece to disconnect Do not kink Clip onto fuel tank
8. T-piece Different versions are available; for correct version: See Parts Catalog Clipped into baffle housing with 2 retaining hooks To remove, press towards the right to release retaining hooks and lift out
9. Fuel line To suction jet pump in baffle housing
10. Fuel return line From left flange
11. Fuel return line From right suction jet pump
12. Baffle housing With suction jet pump

Part II

The following list pertains to see scheme 156.

1. Baffle housing With suction jet pump
2. T-piece Different versions are available; for correct version: See Parts Catalog Clipped into baffle housing with 2 retaining hooks To remove, press towards the right to release retaining hooks and lift out
3. Fuel line To suction jet pump in baffle housing
4. Fuel return line From left flange
5. Fuel return line From engine or fuel filter Press release tab on connection piece to disconnect Do not kink Clip onto fuel tank
6. Seal Replace When installing, fit seal (dry) in fuel tank opening
7. Locking ring Remove and install using wrench 3087 Tighten to 145 Nm
8. Electrical connector For Fuel Level Sensor 2 -G169- Releasing, see «RELEASING CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
9. Flange Only available together with -Item 10 -. Installation position, see «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
10. Fuel Level Sensor 2 -G169- Testing, see «FUEL LEVEL SENSOR 2 -G169-, TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «FUEL LEVEL SENSOR 2 -G169-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Only available together with -Item 9 -.
11. Suction jet pump With lines Different versions are available. For correct version See Parts Catalog Secured on flange Function, see «SUCTION JET PUMP, FUNCTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__suction-jet-pump-function) Removing and installing, see «SUCTION JET PUMP IN LEFT FUEL TANK CHAMBER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
12. Fuel supply line From right suction jet pump

1. To disconnect multi-pin connector at fuel delivery unit, first release retaining catch. This can be done manually or by using a small screwdriver -arrow-.

1. VAG 1348/3A with VAG 1348/3-2
2. VAG 1526 A
3. VAG 1594 A

1. Battery voltage not less than 12.7 V
2. Fuse in fuse holder -S228- OK (plug-in position No. 28)
3. Fuel pump relay (arrow) OK (located at plug-in position No. 1 in nine-way relay carrier behind storage compartment on driver's side)
4. Fuel filter OK
5. Ignition switched off

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- off plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A using adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228-(plug-in position No. 28).
4. Connect clamp to vehicle battery positive (+).
5. Press remote control switch. Pump should start running (audible when standing close to fuel tank).

Note. The fuel pump runs very quietly. Where possible, avoid noisy surroundings for this test.

If pump does not start running

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
2. Detach cover for flange -arrows- (right side).
3. Carefully disengage and remove electrical harness connector -1-(right side of vehicle).
4. Connect multimeter (voltage range) between contacts 1 and 4 of connector.
5. Press remote control switch. Specification: approx. battery voltage

If the specification is not reached

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

If the specification is obtained, even though the fuel pump did not run

1. Remove fuel delivery unit. See «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .
2. Check that the electrical wires between flange and fuel pump are connected and test for continuity.

If no malfunction is detected in the wires, fuel pump is malfunctioning. Replace fuel delivery unit.

1. Install fuel delivery unit. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

1. V.A.G 1318/17-1
2. VAG 1348/3A and VAG 1348/3-2
3. Fuel-resistant measuring container

1. Battery voltage not less than 12.7 V
2. Fuel filter OK
3. Fuel tank at least 1/4 filled
4. Fuel pressure regulator OK, checking: For 1.8L Turbo, see «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__system-pressure-fuel-pressure-regulator-and) .
5. Ignition switched off

Scheme 28

Scheme 29

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- off plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A together using adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28) -arrow-.
4. Connect clamp to vehicle battery (+).
5. Remove filler cap from fuel tank filler neck.
6. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
7. Detach cover for flange -arrows- (right side). WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
8. Remove fuel supply line (arrow) from locking flange (left side of vehicle).
9. Fit adapter V.A.G 1318/17-1 onto disconnected fuel return line and hold pipe in measuring container.
10. Operate remote control for 15 seconds (keep button pressed).
11. Compare the quantity of fuel delivered with specification. *) Minimum delivery cm 3 /15 seconds **) Voltage at fuel pump with engine stationary and pump running (approx. 2 volts less than battery voltage).
12. Connect fuel return hose.

1. VAG 1348/3A and VAG 1348/3-2
2. Fuel-resistant measuring container

1. Battery voltage not less than 12.7 V
2. Fuel filter OK
3. Fuel tank at least 1/4 full.
4. Fuel pressure regulator OK, check: For 3.0L V6, see «FUEL PRESSURE REGULATOR AND HOLDING PRESSURE (VEHICLES UP TO 06.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__fuel-pressure-regulator-and-holding-pressure) .
5. Ignition switched off

Scheme 30

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- out of plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A together with adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28).
4. Connect clamp to vehicle battery positive (+).
5. Remove filler cap from fuel tank filler neck. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
6. Disconnect fuel return hose at connection on fuel distribution pipe (fuel rail).
7. Connect extension hose -arrow- to fuel distribution pipe and hold end of hose in measuring container.
8. Operate remote control for 15 seconds (keep button pressed).
9. Compare the quantity of fuel delivered with specification. *) Minimum delivery cm 3 /15 seconds **) Voltage at fuel pump with engine stationary and pump running (approx. 2 volts less than battery voltage).
10. Connect fuel return hose.

Note. Secure all hose connections with the correct hose clamps (same as original equipment)

See Parts Catalog

1. Wrench for fuel tank sender unit 3087
2. Fuel pump wrench 3307

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove the fuel delivery unit, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system

Scheme 31

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange -arrows- (right side).
5. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
6. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
7. Disconnect supply line -1- from locking flange (right side of vehicle).

1. In addition, disconnect breather pipe -2- to fuel filter from flange.

1. Remove locking ring using wrench for fuel tank sender unit 3087.
2. Remove flange and seal out of opening in fuel tank.
3. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
4. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
5. Turn fuel delivery unit counterclockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -2- (bayonet fitting).
6. Take out fuel delivery unit.

Install in reverse sequence; note the following points

Scheme 32

Scheme 33

Scheme 34

1. 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.
2. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
3. Turn fuel delivery unit clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting).
4. Connect electrical connector -arrow- for fuel gauge sender on inside of flange.
5. Fit new seal for flange in fuel tank opening (seal should be dry).
6. Note the installation position of connector valve: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
7. Tighten locking ring (145 Nm).

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery .

1. Observe safety precautions after connecting the battery.

TIGHTENING TORQUES: FUEL DELIVERY UNIT (ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003)

1. VAG 1526 A
2. VAG 1594 A

Scheme 35

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
2. Detach cover for flange -arrows- (right side).
3. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
4. Connect multimeter (resistance range) between contacts 2 and 3. FUEL GAUGE SENDER RESISTANCE SPECIFICATIONS (SENDER INSTALLED) - ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003 Sender installed Sender at lower impact Sender at upper impact Sender for fuel gauge -G- 295 - 305 ohm 56 - 68 ohm
5. If the resistance is 0 ohm, there is a short circuit. If the resistance is infin ohm, there is an open circuit in the wiring.

Note. To test the maximum and minimum resistance values for "tank full" and "tank empty", remove the fuel gauge sender I, see SENDER FOR FUEL GAUGE -G-, REMOVING AND INSTALLING and move the sender float all the way to its top or bottom position.

When the fuel gauge sender is removed, the arm of the float will travel further and the specifications are

FUEL GAUGE SENDER RESISTANCE SPECIFICATIONS (SENDER REMOVED) - ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003

1. Wrench for fuel tank sender unit 3087

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove the fuel delivery unit, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system

Scheme 36

Scheme 37

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange -arrows- (right side).
5. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
6. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
7. Disconnect supply pipe -arrow- from flange (right side of vehicle).

1. In addition, disconnect breather pipe -2- to fuel filter from flange.

1. Remove locking ring using wrench for fuel tank sender unit 3087.
2. Remove flange and seal out of opening in fuel tank.
3. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
4. Press retaining tab, and at the same time pull the sender out of baffle housing guide -arrows-. NOTE: The baffle housing is shown without the fuel tank for a clearer illustration.

Install in reverse sequence; note the following points

1. Insert fuel gauge sender I into guide on baffle housing and press down until it clicks into place -arrow-.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

1. Reinstall flange (right side). See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) . Observe notes on procedure for connecting battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/charging-system/#generators-regulators) .

1. VAG 1526 A
2. VAG 1594 A

Scheme 38

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
2. Detach cover for flange (left side) -arrows-.
3. Carefully disengage and remove electrical harness connector (left side of vehicle).
4. Connect multimeter (resistance range) between contacts 2 and 3. FUEL LEVEL SENSOR 2 -G169- RESISTANCE SPECIFICATIONS (SENSOR INSTALLED) - ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003 Sender installed Sender at lower impact Sender at upper impact Fuel Level Sensor 2 -G169- 275 - 296 ohm 47 - 65 ohm
5. If the resistance is 0 ohm, there is a short circuit. If the resistance is infin ohm, there is an open circuit in the wiring.

Note. To test the maximum and minimum resistance values for "tank full" and "tank empty", remove the fuel gauge sender II (see FUEL LEVEL SENSOR 2 -G169-, REMOVING AND INSTALLING ) and move the sender float all the way to its top or bottom position.

When the fuel gauge sender is removed, the arm of the float will travel further and the specifications are

FUEL LEVEL SENSOR 2 -G169- RESISTANCE SPECIFICATIONS (SENSOR REMOVED) - ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003

1. Wrench for fuel tank sender unit 3087

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove Fuel gauge sender II, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system

Scheme 39

Scheme 40

Scheme 41

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange (left side) -arrows-.
5. Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle). WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
6. Disconnect fuel return pipe -arrow- from flange (left side of vehicle). CAUTION: Fuel gauge sender II flange must only be removed with the fuel tank not more than 1/4 full. Otherwise a great amount of fuel flows out.
7. Remove locking ring (left side of vehicle) using wrench for fuel gauge sender unit 3087.
8. Carefully pull flange with fuel gauge sender II a short distance out of fuel tank opening together with seal.
9. First pull fuel line -1- out of fuel tank.
10. Swivel flange -2- with fuel gauge sender II -3- and suction jet pump -4- out of fuel tank opening.. NOTE: Take care not to bend the arm of the float when removing sender II.
11. Unclip suction jet pump from flange with fuel gauge sender II.
12. Press release catches -arrows- and disconnect fuel line at Y-connector.
13. Remove sealing flange with fuel gauge sender II.

Install in reverse sequence; note the following points

Scheme 42

1. Fit new seal for flange of fuel gauge sender II in fuel tank opening (seal should be dry).
2. Note fitting position of flange of fuel gauge sender II: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
3. Tighten locking ring (145 Nm).

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) for connecting Telematics battery

1. Observe safety precautions after connecting the battery.

TIGHTENING TORQUES: FUEL LEVEL SENSOR 2 -G169- (ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003)

Suction jet pump, function

Note. The arrow points in direction of travel.

On vehicles with four-wheel drive the fuel tank is divided into a left and a right chamber.

The fuel is delivered from the left fuel tank chamber to the baffle housing -8- of the fuel delivery unit in the right fuel tank chamber by means of a suction jet pump -1-.

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 operate according to the principle of fluid entertainment: a stream of fuel from the fuel return pipe -3- is passed through a nozzle in each individual suction jet pump -1- and -7-, and is thus accelerated. The accelerated stream of fuel draws off the surrounding fuel and delivers it to the baffle housing of the fuel delivery unit. The right suction jet pump -7- delivers the fuel directly into the baffle housing, the left suction jet pump -1- delivers the fuel via a separate pipe -4-.

The fuel is distributed from the return pipe to the two suction jet pumps via the Y-connector -2-.

At the same time the connecting piece -6- limits the pressure in the lines to the suction jet pumps to approx. 1 bar. Excess fuel is delivered directly to the baffle housing via a pipe.

5 - Fuel supply line

Scheme 43

1. Wrench for fuel tank sender unit 3087
2. Fuel pump wrench 3307

Note. This section describes how to remove the suction jet pump in the left fuel tank chamber. The suction jet pump in the right fuel tank chamber is part of the baffle housing and cannot be replaced separately.

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove the suction jet pump, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) before beginning repairs on the electrical system .

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange -arrows- (right side).
5. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
6. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
7. Disconnect supply pipe -arrow- from flange (right side of vehicle).

1. In addition, disconnect breather pipe -2- to fuel filter at locking flange.

Scheme 44

Scheme 45

1. Remove locking ring using wrench for fuel tank sender unit 3087.
2. Remove flange and seal out of opening in fuel tank.
3. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
4. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
5. Turn fuel delivery unit counterclockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -2- (bayonet fitting).
6. Take out fuel delivery unit.
7. Detach cover for flange (left side) -arrows-.
8. Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle). WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
9. Disconnect return line -arrow- from flange (left side of vehicle).
10. Remove locking ring (left side of vehicle) using wrench for fuel gauge sender unit 3087.
11. Carefully pull flange with fuel gauge sender II a short distance out of fuel tank opening together with seal.
12. Pull fuel pipe -1- out of fuel tank.
13. Swivel flange -2- with fuel gauge sender II -3- and suction jet pump -4- out of fuel tank opening. NOTE: Take care not to bend the arm of the float when removing fuel gauge sender II.
14. Unclip suction jet pump from flange with fuel gauge sender II.
15. Press release catches -arrows- and disconnect fuel pipe at Y-connector.
16. Pull fuel supply pipe -4- out of baffle housing.
17. Press connecting piece -1- to the right and unclip it from baffle housing.
18. Disconnect fuel return pipe -3- at connecting piece -1-. NOTE: Fuel pipe -2- remains connected.
19. Reach into fuel tank opening on left side of vehicle and pull out suction jet pump with lines towards the left.

Install in reverse sequence; note the following points

Scheme 46

Scheme 47

Scheme 48

1. Push suction jet pump (with lines fitted) into fuel tank opening on left side of vehicle.
2. Reach into fuel tank opening on right side of vehicle and pull suction jet pump with hoses into their final position.
3. Press return pipe -3- onto connecting piece -1- so that the hose connectors engage.
4. Clip connecting piece onto baffle housing.
5. Fit fuel supply pipe -4- into corresponding hole in baffle housing.
6. Clip suction jet pump onto flange of fuel gauge sender II and attach fuel pipe to Y-connector.
7. Swivel flange with sender II and suction jet pump out of fuel tank.
8. Note fitting position of flange of fuel gauge sender II: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
9. Tighten locking ring (145 Nm).
10. 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.
11. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
12. Turn fuel delivery unit clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting).
13. Connect electrical connector -arrow- for fuel gauge sender on inside of flange.
14. Fit new seal for flange in fuel tank opening (seal should be dry).
15. Note fitting position of flange: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
16. Tighten locking ring (145 Nm).

See (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES UP TO 06.2003 ) Caution for connecting Telematics battery

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

TIGHTENING TORQUES: SUCTION JET PUMP (ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003)

The Fuel Tank Lock Switch -F314- consists of a reed contact on the fuel filler tube and a fuel filler cap with an embedded magnet.

If the fuel filler cap is not fully bolted on, the reed contact switches and triggers an indication on the display in instrument cluster.

Scheme 49

1. Check the following items in order with a lighted display: Fuel filler cap is installed and threaded in tightly Proper fuel filler cap (recognized by: threads are colored gray) Switch (arrow) is fully inserted at fuel filler tube Electrical malfunction in switch. Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__electrical-test-for-fuel-tank-lock) Faulty wiring connection to instrument cluster (check according to wiring diagram)

Electrical test for Fuel Tank Lock Switch -F314

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than 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 locking flange (arrows).
3. Disconnect electrical harness connector -2-.
4. Connect multimeter between terminals 1 and 2 for resistance measurement.

FUEL TANK LOCK SWITCH -F314- RESISTANCE (ALL-WHEEL DRIVE, VEHICLES UP TO 06.2003)

If specified values are not obtained

1. Right-rear wheelhousing liner, removing: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
2. Replace Fuel Tank Lock Switch -F314- (arrow), to do this, unclip switch and electrical wire to fuel filler tube and reclip them afterward.

Note. Secure all hose connections with the correct hose clamps (same as original equipment) => Parts Catalog Hose clip pliers VAG 1921 are recommended when installing spring-type clamps. Always replace seals and gaskets when assembling.

The following list pertains to see scheme 249.

1. Bracket For exhaust system
2. Carrier plate
3. Fuel supply line From fuel filter To engine Do not kink Press release tab on connection piece to disconnect
4. Ventilation line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Do not kink Press release tab on connection piece to disconnect Clip onto fuel tank
5. Electrical harness connector For Fuel Tank Lock Switch -F314- Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
6. 2 Nm
7. Heat shield for fuel filler neck
8. 23 Nm Secures fuel filler neck and ground connection - Item 14
9. Overflow hose
10. Rubber cup
11. Retaining ring
12. Seal Always replace if damaged
13. Filler cap
14. Ground connection To eliminate electrostatic charge Position / test procedure, see «POSITION OF GROUND CONNECTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Make sure that connector is seated properly and secure wire with fastening bolt for fuel filler neck -Item 8 - 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 ohm
15. Ventilation pipe
16. Ventilation pipe From gravity valve to EVAP canister To remove, press release ring on EVAP canister
17. Ventilation pipe From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- To remove, press release ring on EVAP canister Clip onto fuel tank
18. Fuel tank Removing and installing, see «FUEL TANK WITH ATTACHMENTS, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
19. Spreader clip
20. 23 Nm
21. Securing strap
22. Heat shield For fuel tank
23. 2 Nm
24. 23 Nm

1. Route ground connection as shown in illustration.
2. First hook ground connection contact -1- into mounting hole on fuel tank -5- and then press in spacer sleeve -2-.
3. Make sure that ground connection connector -4- is properly seated on metal ring -3- on fuel filler neck.

1. Specification: approx. 0 ohms .

1. Wrench for fuel tank sender unit 3087
2. VAS 5190

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system

Scheme 50

Scheme 51

Scheme 52

1. With ignition switched off disconnect battery ground strap. WARNING: Secure ground wire of VAS 5190 to a bare metal part on the body.
2. Detach tapered adapter -2- from shaft end -1- of VAS 5190.
3. Make a mark -arrow- on hose at distance a = 1865 mm from end of drain hose using insulating tape.
4. Remove filler cap from fuel tank filler neck.
5. Fit shaft end -1- of fuel extractor VAS 5190 onto fuel tank filler neck.
6. Push drain hose into fuel tank until marking on drain 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 drain hose at distance a = 1800 mm from end of drain hose using insulating tape. The drain hose is fitted properly when marking on drain hose coincides with rim of filler neck. If the hose does not go in easily, lubricate lightly with engine oil. Do not use silicone lubricant.
7. Drain tank as far as possible via fuel filler neck.
8. Carefully pull out drain hose.
9. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
10. Detach cover for flange -arrows- (right side).
11. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
12. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
13. Disconnect fuel supply pipe -1- from locking flange (right side of vehicle).
14. Disconnect ventilation pipe -2- (press release button).
15. Unscrew locking ring using wrench for fuel tank sender unit 3087.
16. Remove flange and seal out of opening in fuel tank.
17. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
18. Insert drain hose to marking x = 800 mm through right opening in fuel tank and into left fuel chamber.
19. Draw off fuel from left chamber of fuel tank.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery

1. Re-install flange (right side), see «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) . Observe notes on procedure for connecting battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/charging-system/#generators-regulators) .

1. VAG 1383 A and VAG 1359/2

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. Drain fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system .

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.

1. Detach trim in luggage compartment.
2. Fold down right rear seat backrest if necessary.

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

Scheme 53

1. Unscrew cover -arrows-.
2. Disconnect ventilation pipe -1-. To do so, press unlocking ring -2- approx. 2mm in direction of arrow -A- and disconnect ventilation pipe(arrow B).
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange (left and right side) -arrows-.
5. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
6. Disconnect electrical harness connector -2-.
7. Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle).
8. Remove right-rear wheel.
9. Remove right-rear right wheel housing liner: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
10. Clean area around tank filler neck.
11. Pry out clamping ring -arrow- in rubber cup (on filler neck). NOTE: Do not remove filler cap.
12. Press rubber cup through to the inside.
13. Remove rear section of exhaust system: For 1.8L Turbo engines, see «EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#engine-controls-turbocharger-exhaust-system-emission-controls-18l-5v-turbo-amb__exhaust-system-components-removing-and-installing) . For 3.0L V6 engines, see «EXHAUST SYSTEM, SERVICING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-servicing) . For 4.2L V8, see «EXHAUST COMPONENTS, REMOVING AND INSTALLING»(ref-197062-S17437019812005101100000) .
14. Remove propshaft: See «DRIVESHAFT & UNIVERSAL JOINTS - 01V (AWD TRANSAXLE)»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle) . CAUTION: Secure vehicle against tipping over before LOOSENING the subframe bolts (e.g. load trunk compartment with approx. 50 kg).
15. Remove rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear) WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
16. Disconnect fuel supply hose -1- from fuel filter (press release button) and catch escaping fuel.
17. Disconnect ventilation pipe -2- (press release button).
18. Disconnect ventilation line -2- from fuel filler neck (press release buttons).
19. Remove bolt -1- for fuel filler neck.
20. Remove EVAP canister cover at bottom of spare tire well (arrows).
21. Disconnect ventilation lines -1- and -2-. To do so, press release ring -3- in direction of arrow -A- and pull off ventilation line (arrow -B-).
22. Unclip ventilation lines at top from bracket (arrow).
23. Detach heat shields -1- and -2-.
24. Detach handbrake cables from the retainers marked by arrows.
25. Position engine/transmission hoist VAG 1383 A below vehicle to support tank. WARNING: The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.
26. Take out bolts -1 through 10-.
27. Lower fuel tank with carrier plate.

Install in reverse sequence; note the following points

Note. Secure all hose connections using the correct type of hose clamps (as original equipment): See Parts Catalog

1. Check that supply hoses, return hoses and ventilation lines are clipped onto fuel tank.
2. Check the ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.
3. Check Position Of Ground Connection: Make sure connector -4- is connected securely on metal ring -3-. Contact tab -1- must be hooked onto the fuel tank -5- and secured with spacer sleeve -2-.
4. Position fuel tank with securing straps and carrier plate on underside of vehicle using engine/transmission jack VAG 1383 A.
5. Tighten bolts -1 through.10- for securing straps and carrier plate to 23 Nm.
6. Secure fuel filler neck (23 Nm). CAUTION: 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 ohms
7. Install rear axle: See «SUSPENSION - REAR»(/audi/a4/b6-2000-2006/remont/suspension-rear/#suspension-rear)
8. Install propshaft: See «DRIVESHAFT & UNIVERSAL JOINTS - 01V (AWD TRANSAXLE)»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle) .
9. Install rear part of exhaust system: For 1.8L Turbo engines, see «EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#engine-controls-turbocharger-exhaust-system-emission-controls-18l-5v-turbo-amb__exhaust-system-components-removing-and-installing) . For 3.0L V6 engines, see «EXHAUST SYSTEM, SERVICING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-servicing) . For 4.2L V8, see «EXHAUST COMPONENTS, REMOVING AND INSTALLING»(ref-197062-S17437019812005101100000) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery

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

TIGHTENING TORQUES: FUEL TANK (ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003)

The following list pertains to see scheme 278.

1. Sender for fuel gauge -G- Clipped onto reservoir housing in fuel tank Checking resistance, see «SENDER FOR FUEL GAUGE -G-, TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «SENDER FOR FUEL GAUGE -G-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
2. Fuel delivery unit Different versions are available; for correct version: See Parts Catalog Can only be replaced together with flange Checking fuel pump (electrical test), see «FUEL PUMP, TESTING (ELECTRICAL TEST)»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Checking delivery rate, see «FUEL PUMP DELIVERY RATE, CHECKING - VEHICLES WITH 4-CYL. TURBO ENGINE, 6-CYL. AND 8-CYL. ENGINE»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) . Checking holding pressure: For 1.8L Turbo, see «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__system-pressure-fuel-pressure-regulator-and) . For 3.0L V6, see «SYSTEM PRESSURE AND HOLDING PRESSURE (VEHICLES AS OF 07.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__system-pressure-and-holding-pressure-vehicles) . For 4.2L V8, see «FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, CHECKING»(ref-213322-S07247353192005122900000) . Removing and installing, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
3. Electrical connector For fuel pump and Sender for fuel gauge -G- Releasing, see «RELEASING CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
4. Flange For fuel delivery unit Cannot be replaced separately Installation position, see «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
5. Breather pipe from fuel pressure regulator in fuel filter Press release tab on connection piece to disconnect do not kink clip on fuel tank
6. Seal Replace When installing, fit seal (dry) in fuel tank opening
7. Locking ring Remove and install using wrench 3087 Tighten to 145 Nm
8. Fuel supply line To fuel filter Press release tab on connection piece to disconnect Do not kink Clip onto fuel tank
9. T-piece Different versions are available; for correct version: See Parts Catalog Clipped into baffle housing with 2 retaining hooks To remove, press towards the right to release retaining hooks and lift out
10. Fuel line To suction jet pump in baffle housing
11. Fuel return line From left flange
12. Fuel return line From right suction jet pump
13. Baffle housing With suction jet pump

The following list pertains to see scheme 279.

1. Baffle housing With suction jet pump
2. T-piece Different versions are available; for correct version: See Parts Catalog Clipped into baffle housing with 2 retaining hooks To remove, press towards the right to release retaining hooks and lift out
3. Fuel line To suction jet pump in baffle housing
4. Fuel return line From left flange
5. Fuel return line From engine or fuel filter Press release tab on connection piece to disconnect Do not kink Clip onto fuel tank
6. Seal Replace When installing, fit seal (dry) in fuel tank opening
7. Locking ring Remove and install using wrench 3087 Tighten to 145 Nm
8. Electrical connector For Fuel Level Sensor 2 -G169- Releasing, see «RELEASING CONNECTOR»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
9. Flange Only available together with -Item 10 -. Installation position, see «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
10. Fuel Level Sensor 2 -G169- Testing, see «FUEL LEVEL SENSOR 2 -G169-, TESTING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «FUEL LEVEL SENSOR 2 -G169-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Only available together with -Item 9 -.
11. Suction jet pump With lines Different versions are available. For correct version: See Parts Catalog Secured on flange Function, see «SUCTION JET PUMP, FUNCTION»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «SUCTION JET PUMP IN LEFT FUEL TANK CHAMBER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
12. Fuel supply line From right suction jet pump

1. To disconnect multi-pin connector at fuel delivery unit, first release retaining catch. This can be done manually or by using a small screwdriver -arrow-.

1. VAG 1348/3A with VAG 1348/3-2
2. VAG 1526 A
3. VAG 1594 A

1. Battery voltage not less than 12.7 V
2. Fuse in fuse holder -S228- OK (plug-in position No. 28)
3. Fuel pump relay (arrow) OK (located at plug-in position No. 1 in nine-way relay carrier behind storage compartment on driver's side)
4. Fuel filter OK
5. Ignition switched off

Scheme 54

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- off plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A using adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28).
4. Connect clamp to vehicle battery positive (+).
5. Press remote control switch. Pump should start running (audible when standing close to fuel tank). NOTE: The fuel pump runs very quietly. Where possible, avoid noisy surroundings for this test. If pump does not start running
6. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
7. Detach cover for flange -arrows- (right side).
8. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
9. Connect multimeter (voltage range) between contacts 1 and 4 of connector.
10. Press remote control switch. Specification: approx. battery voltage

If the specification is not reached

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

If the specification is obtained, even though the fuel pump did not run

1. Remove fuel delivery unit. See «FUEL DELIVERY UNIT, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .
2. Check that the electrical wires between flange and fuel pump are connected and test for continuity.

If no malfunction is detected in the wires, fuel pump is malfunctioning. Replace fuel delivery unit.

1. Install fuel delivery unit. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

1. V.A.G 1318/17-1
2. VAG 1348/3A and VAG 1348/3-2
3. Fuel-resistant measuring container

1. Battery voltage not less than 12.7 V
2. Fuel filter OK
3. Fuel tank at least 1/4 filled
4. Fuel pressure regulator OK, checking: For 1.8L Turbo, see «SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__system-pressure-fuel-pressure-regulator-and) . For 3.0L V6, see «SYSTEM PRESSURE AND HOLDING PRESSURE (VEHICLES AS OF 07.03), CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__system-pressure-and-holding-pressure-vehicles) . For 4.2L V8, see «FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, CHECKING»(ref-213322-S07247353192005122900000) .
5. Ignition switched off

Scheme 55

Scheme 56

1. Open fuse box cover on the left side of the instrument panel.
2. Pull Fuse in fuse holder -S228- off plug-in position 28 of fuse carrier (left row, 5th large fuse from the top).
3. Connect remote control VAG 1348/3A together using adapter cable VAG 1348/3-2 to right-hand fuse socket terminal of Fuse in fuse holder -S228- (plug-in position No. 28) -arrow-.
4. Connect clamp to vehicle battery (+).
5. Remove filler cap from fuel tank filler neck.
6. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
7. Detach cover for flange -arrows- (right side). WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
8. Remove fuel supply line (arrow) from locking flange (left side of vehicle).
9. Fit adapter V.A.G 1318/17-1 onto disconnected fuel return line and hold line in measuring container.
10. Operate remote control for 15 seconds (keep button pressed).
11. Compare the quantity of fuel delivered with specification. *) Minimum delivery cm 3 /15 seconds **) Voltage at fuel pump with engine stationary and pump running (approx. 2 volts less than battery voltage).
12. Connect fuel return hose.

1. Wrench for fuel tank sender unit 3087
2. Fuel pump wrench 3307

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove the fuel delivery unit, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system .

Scheme 57

Scheme 58

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange -arrows- (right side).
5. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
6. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
7. Disconnect fuel supply line -1- and breather pipe -2- from locking flange (right side of vehicle; press release button). CAUTION: The locking flange must only be opened with the fuel tank not more than 1 /4 full. Otherwise a great amount of fuel flows out.
8. Remove locking ring using wrench for fuel tank sender unit 3087.
9. Remove flange and seal out of opening in fuel tank.
10. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
11. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
12. Turn fuel delivery unit counterclockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -2- (bayonet fitting).
13. Take out fuel delivery unit.

Install in reverse sequence; note the following points

Scheme 59

Scheme 60

Scheme 61

1. 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.
2. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
3. Turn fuel delivery unit clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting).
4. Connect electrical connector -arrow- for fuel gauge sender on inside of flange.
5. Fit new seal for flange in fuel tank opening (seal should be dry).
6. Note the installation position of connector valve: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
7. Tighten locking ring (145 Nm).

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery

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

TIGHTENING TORQUES: FUEL DELIVERY UNIT (ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003)

1. VAG 1526 A
2. VAG 1594 A

Scheme 62

Scheme 63

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
2. Detach cover for flange -arrows- (right side).
3. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
4. Connect multimeter (resistance range) between contacts 2 and 3. FUEL GAUGE SENDER RESISTANCE (SENDER INSTALLED) - ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003 Sender installed Sender at lower impact Sender at upper impact Sender for fuel gauge -G- 295 - 305 ohm 56 - 68 ohm
5. If the resistance is 0 ohm, there is a short circuit. If the resistance is infin ohm, there is an open circuit in the wiring.

Note. To test the maximum and minimum resistance values for "tank full" and "tank empty", remove the fuel gauge sender I. See SENDER FOR FUEL GAUGE -G-, REMOVING AND INSTALLING and move the sender float all the way to its top or bottom position.

When the fuel gauge sender is removed, the arm of the float will travel further and the specifications are

FUEL GAUGE SENDER RESISTANCE (SENDER INSTALLED) - ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003

1. Wrench for fuel tank sender unit 3087

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove the fuel delivery unit, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system

Scheme 64

Scheme 65

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange -arrows- (right side).
5. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
6. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
7. Disconnect supply pipe -1- from locking flange (right side of vehicle).
8. Disconnect breather pipe -2- (press release button). CAUTION: The locking flange must only be opened with the fuel tank not more than 1/4 full. Otherwise a great amount of fuel flows out.
9. Remove locking ring using wrench for fuel tank sender unit 3087.
10. Remove flange and seal out of opening in fuel tank.
11. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
12. Press retaining tab, and at the same time pull the sender out of baffle housing guide -arrows-. NOTE: The baffle housing is shown without the fuel tank for a clearer illustration.

Install in reverse sequence; note the following points

1. Insert fuel gauge sender l into guide on baffle housing and press down until it clicks into place -arrow-.

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery

1. Reinstall flange (right side). See «INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) . Observe notes on procedure for connecting battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/charging-system/#generators-regulators) .

1. VAG 1526 A
2. VAG 1594 A

Scheme 66

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
2. Detach cover for flange (left side) -arrows-.
3. Carefully disengage and remove electrical harness connector (left side of vehicle).
4. Connect multimeter (resistance range) between contacts 2 and 3. FUEL LEVEL SENSOR 2 -G169- RESISTANCE (SENSOR INSTALLED) - ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003 Sender installed Sender at lower impact Sender at upper impact Fuel Level Sensor 2 -G169- 275 - 296 ohm 47 - 65 ohm
5. If the resistance is 0 ohm, there is a short circuit. If the resistance is ohm, there is an open circuit in the wiring.

Note. To test the maximum and minimum resistance values for "tank full" and "tank empty", remove the fuel gauge sender II (see fuel Level Sensor 2 -G169-, Removing And Installing ) and move the sender float all the way to its top or bottom position.

When the fuel gauge sender is removed, the arm of the float will travel further and the specifications are

FUEL LEVEL SENSOR 2 -G169- RESISTANCE (SENSOR REMOVED) - ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003

1. Wrench for fuel tank sender unit 3087

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove Fuel gauge sender II, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system .

Scheme 67

Scheme 68

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange (left side) -arrows-.
5. Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle). WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
6. Disconnect fuel return pipe -arrow- from flange (left side of vehicle). CAUTION: Fuel gauge sender II flange must only be removed with the fuel tank not more than 1/4 full. Otherwise a great amount of fuel flows out.
7. Remove locking ring (left side of vehicle) using wrench for fuel gauge sender unit 3087.
8. Carefully pull flange with fuel gauge sender II a short distance out of fuel tank opening together with seal.
9. First pull fuel line -1- out of fuel tank.
10. Swivel flange -2- with fuel gauge sender II -3- and suction jet pump -4- out of fuel tank opening.. NOTE: Take care not to bend the arm of the float when removing sender II.
11. Unclip suction jet pump from flange with fuel gauge sender II.
12. Press release catches -arrows- and disconnect fuel line at Y-connector.
13. Remove sealing flange with fuel gauge sender II.

Install in reverse sequence; note the following points

Scheme 69

1. Fit new seal for flange of fuel gauge sender II in fuel tank opening (seal should be dry).
2. Note fitting position of flange of fuel gauge sender II: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
3. Tighten locking ring (145 Nm).

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery .

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

TIGHTENING TORQUES: FUEL LEVEL SENSOR 2 -G169- (ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003)

Note. The arrow points in direction of travel.

On vehicles with four-wheel drive the fuel tank is divided into a left and a right chamber.

The fuel is delivered from the left fuel tank chamber to the baffle housing -8- of the fuel delivery unit in the right fuel tank chamber by means of a suction jet pump -1-.

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 operate according to the principle of fluid entrainment: a stream of fuel from the fuel return pipe -3- is passed through a nozzle in each individual suction jet pump -1- and -7-, and is thus accelerated. The accelerated stream of fuel draws off the surrounding fuel and delivers it to the baffle housing of the fuel delivery unit. The right suction jet pump -7- delivers the fuel directly into the baffle housing, the left suction jet pump -1- delivers the fuel via a separate pipe -4-.

The fuel is distributed from the return pipe to the two suction jet pumps via the Y-connector -2-.

At the same time the connecting piece -6- limits the pressure in the lines to the suction jet pumps to approx. 1 bar. Excess fuel is delivered directly to the baffle housing via a pipe.

5 - Fuel supply line

Scheme 70

1. Wrench for fuel tank sender unit 3087
2. Fuel pump wrench 3307

Note. This section describes how to remove the suction jet pump in the left fuel tank chamber. The suction jet pump in the right fuel tank chamber is part of the baffle housing and cannot be replaced separately.

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. To remove the suction jet pump, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) before beginning repairs on the electrical system .

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. With ignition switched off disconnect battery ground strap.
2. Open fuel filler cap briefly, then close it again.
3. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
4. Detach cover for flange -arrows- (right side).
5. Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
6. Disconnect electrical harness connector -2- and set it aside. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
7. Disconnect fuel supply pipe -1- from locking flange (right side of vehicle).
8. Disconnect breather pipe -2- (press release button). CAUTION: The locking flange must only be opened with the fuel tank not more than 1/4 full. Otherwise a great amount of fuel flows out.
9. Remove locking ring using wrench for fuel tank sender unit 3087.
10. Remove flange and seal out of opening in fuel tank.
11. Disconnect connector -arrow- for fuel gauge sender on inside of flange.
12. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
13. Turn fuel delivery unit counterclockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -2- (bayonet fitting).
14. Take out fuel delivery unit.
15. Detach cover for flange (left side) -arrows-.
16. Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle). WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
17. Disconnect return line -arrow- from flange (left side of vehicle).
18. Remove locking ring (left side of vehicle) using wrench for fuel gauge sender unit 3087.
19. Carefully pull flange with fuel gauge sender II a short distance out of fuel tank opening together with seal.
20. Pull fuel pipe -1- out of fuel tank.
21. Swivel flange -2- with fuel gauge sender II -3- and suction jet pump -4- out of fuel tank opening. NOTE: Take care not to bend the arm of the float when removing fuel gauge sender II.
22. Unclip suction jet pump from flange with fuel gauge sender II.
23. Press release catches -arrows- and disconnect fuel pipe at Y-connector.
24. Pull fuel supply pipe -4- out of baffle housing.
25. Press connecting piece -1- to the right and unclip it from baffle housing.
26. Disconnect fuel return pipe -3- at connecting piece -1-. NOTE: Fuel pipe -2- remains connected.
27. Reach into fuel tank opening on left side of vehicle and pull out suction jet pump with lines towards the left.

Install in reverse sequence; note the following points

Scheme 75

Scheme 76

1. Push suction jet pump (with lines fitted) into fuel tank opening on left side of vehicle.
2. Reach into fuel tank opening on right side of vehicle and pull suction jet pump with hoses into their final position.
3. Press return pipe -3- onto connecting piece -1- so that the hose connectors engage.
4. Clip connecting piece onto baffle housing.
5. Fit fuel supply pipe -4- into corresponding hole in baffle housing.
6. Clip suction jet pump onto flange of fuel gauge sender II and attach fuel pipe to Y-connector.
7. Swivel flange with sender II and suction jet pump out of fuel tank.
8. Note fitting position of flange of fuel gauge sender II: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
9. Tighten locking ring (145 Nm).
10. 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.
11. Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
12. Turn fuel delivery unit clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting).
13. Connect electrical connector -arrow- for fuel gauge sender on inside of flange.
14. Fit new seal for flange in fuel tank opening (seal should be dry).
15. Note fitting position of flange: Lug -2- on flange must be between tabs -1- and -3- on fuel tank. NOTE: Arrow points in direction of travel.
16. Tighten locking ring (145 Nm).

See Caution (at the beginning of FUEL SUPPLY SYSTEM (ALL-WHEEL DRIVE) - VEHICLES AS OF 07.2003 ) for connecting Telematics battery

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

TIGHTENING TORQUES: SUCTION JET PUMP (ALL-WHEEL DRIVE, VEHICLES AS OF 07.2003)

The Fuel Tank Lock Switch -F314- consists of a reed contact on the fuel filler tube and a fuel filler cap with an embedded magnet.

If the fuel filler cap is not fully bolted on, the reed contact switches and triggers an indication on the display in instrument cluster.

Scheme 77

1. Check the following items in order with a lighted display: Fuel filler cap is installed and threaded in tightly Proper fuel filler cap (recognized by: threads are colored gray) Switch (arrow) is fully inserted at fuel filler tube Electrical malfunction in switch. Checking, see «ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Faulty wiring connection to instrument cluster (check according to wiring diagram).

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than 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 locking flange (arrows).
3. Disconnect electrical harness connector -2-.
4. Connect multimeter between terminals 1 and 2 for resistance measurement.

FUEL TANK LOCK SWITCH -F314- RESISTANCE SPECIFICATIONS

If specified values are not obtained

1. Right-rear wheelhousing liner, removing: For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
2. Replace Fuel Tank Lock Switch -F314- (arrow), to do this, unclip switch and electrical wire to fuel filler tube and reclip them afterward.

Fuel filter, servicing

Special tools and equipment

1. Drip tray

Observe safety precautions, see SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. Remove cover panel located to the right of fuel tank - arrows-.
2. Place container under fuel filter. WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
3. Disconnect fuel line from fuel filter as follows: Fuel return line Fuel supply line from fuel tank Fuel supply line to engine Ventilation line
4. Remove bolt -5-.
5. Remove fuel filter.

Install in reverse sequence; note the following points

1. The arrows point in direction of flow.
2. Marking -2- on bracket must face arrow -1- on fuel filter.
3. The connection points of the fuel lines are marked on the filter.

1. Fuel return pipe "RL"
2. Fuel supply pipe from fuel tank "VL"
3. Fuel supply pipe to engine "MOTOR"
4. Ventilation line "E"

TIGHTENING TORQUE: FUEL FILTER

1. Remove right cover next to fuel tank (arrows).
2. Place appropriate receptacle underneath fuel filter. WARNING: The fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
3. Removed fuel lines -1- and -3- (press release button).
4. Remove bolt -2-.
5. Remove fuel filter.

Installation is reverse of removal, noting the following

1. The direction of flow is marked with arrows
2. Arrow markings -1- and -2- must face each other

TIGHTENING TORQUE: FUEL FILTER

To prevent damage to Three Way Catalytic Converter (TWC) the fuel system without return hose must be bled at fuel lines or at fuel filter after repair work. The vehicle must be started first after bleeding.

Fuel system, bleeding

See FUEL SYSTEM, BLEEDING .

Vehicles with 6-cyl. and 8-cyl. engine as of 07.2003

The fuel system bleeds itself when starting the engine.

EVAP canister/leak detection system, servicing (front-and all-wheel drive vehicles)

The following list pertains to see scheme 375.

1. Cap nut - 10 Nm
2. Cover For EVAP canister
3. Stud bolt - 15 Nm
4. Sealing piece
5. Ventilation line From gravity valve at fuel tank To remove, press release ring on EVAP canister
6. Ventilation 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 Nm
9. Vacuum line To Leak detection pump (LDP) -V144
10. Cable ties For securing vacuum line to Leak Detection Pump (LDP) bracket
11. Leak detection pump (LDP) -V144- Installation location: Under wheel housing liner in rear left wheel housing Checking, see «LEAK DETECTION PUMP (LDP) -V144-, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
12. Electrical harness connector Black
13. Connection hose Leak Detection Pump (LDP)/EVAP canister Pressure side To remove, press release button at connection on (LDP)
14. Connection hose Leak Detection Pump (LDP)/air filter
15. Cable ties For securing hose to Leak Detection Pump (LDP) bracket
16. Sealing piece
17. Cable ties For securing connection hose to wheel housing
18. EVAP canister Installation location: Bottom of spare tire well Removing and installing, see «EVAP CANISTER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__evap-canister-removing-and-installing)

EVAP canister, removing and installing

Note. Checking seal, performing diagnostic leak test, see EVAPORATIVE EMISSIONS (EVAP) SYSTEM DIAGNOSTIC LEAK TEST, PERFORMING

1. Remove EVAP canister cover at bottom of spare tire well.
2. Remove sealing pieces above ventilation lines.
3. Remove connection hose -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 -B-.
5. Remove pin bolts (arrows) and remove EVAP canister.

Installation is reverse of removal, noting the following

Note. Secure all hose connections using hose clamps appropriate for the model type: See Parts Catalog

TIGHTENING TORQUES: EVAP CANISTER

EVAP canister and Leak Detection Pump (LDP), hose diagram (4-cylinder engines)

The following list pertains to see scheme 377.

1. Check-valve Installation position (light/dark side): Arrow on valve points in direction of flow, as shown in figure.
2. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Installation location: right-front in engine compartment.
3. Ventilation 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. Ventilation line To gravity valve on fuel tank.
5. EVAP canister Installation location: Bottom of spare tire well. Removing and installing, see «EVAP CANISTER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__evap-canister-removing-and-installing)
6. Connection hose Leak Detection Pump (LDP) to EVAP canister. Pressure side.
7. Air filter housing For Leak detection pump (LDP) -V144
8. Leak detection pump (LDP) -V144- Installation location: Under wheel housing liner in rear left wheel housing Checking, see «LEAK DETECTION PUMP (LDP) -V144-, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
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 figure.
11. T-piece Installation location, see «INSTALLATION POSITION OF T-PIECE»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__installation-position-of-t-piece)
12. Throttle Valve Control Module -J338

Installation position of T-piece

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

Scheme 78

EVAP canister and Leak Detection Pump (LDP), hose diagram (6-cylinder engines)

The following list pertains to see scheme 379.

1. Throttle Valve Control Module -J338
2. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Installation location: right-front in engine compartment
3. Ventilation 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. Ventilation line To gravity valve on fuel tank
5. EVAP canister Installation location: Bottom of spare tire well Removing and installing, see «EVAP CANISTER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__evap-canister-removing-and-installing)
6. Connection hose Leak Detection Pump (LDP) to EVAP canister Pressure side
7. Air filter housing For Leak detection pump (LDP) -V144
8. Leak detection pump (LDP) -V144- Installation location: Under wheel housing liner in rear left wheel housing Checking, see «LEAK DETECTION PUMP (LDP) -V144-, CHECKING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) Removing and installing, see «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
9. Vacuum line To Leak detection pump (LDP) -V144

EVAP canister and Leak Detection Pump (LDP), hose diagram (8-cylinder engines)

The following list pertains to see scheme 380.

1. Throttle Valve Control Module -J338
2. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Component location: Front right in engine compartment Checking: See «EVAPORATIVE EMISSION (EVAP) CANISTER PURGE REGULATOR VALVE -N80»(ref-213322-S19215100462006022200000)
3. Ventilation 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. Ventilation line to gravity valve on fuel tank
5. EVAP canister Component location: Bottom of spare tire well
6. Connection hose Leak Detection Pump (LDP)/EVAP canister Pressure side
7. Leak detection pump (LDP) -V144- Component location: Under wheel housing liner in rear left wheelhousing
8. Air filter for Leak detection pump (LDP) -V144
9. Vacuum line to Leak detection pump (LDP) -V144
10. Vacuum reservoir for Leak detection pump (LDP) -V144- Component location: Under wheel housing liner in front left wheel housing
11. Separating point Component location, see «INSTALLATION LOCATION OF SEPARATING POINT»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__installation-location-of-separating-point)
12. Check-valve Installation position (light/dark side): Arrow points in direction of flow, as shown in figure.

Installation location of separating point

The separating point (arrow) is located on the left-hand side of the engine compartment.

1. To disconnect, press release button on connection piece

Function

The Evaporative Emissions (EVAP) system, diagnostic leak test recognizes leaks in the entire fuel system including the fuel tank, 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 its vacuum via the engine intake.

1. When the diagnostic leak test is activated, the Leak Detection Pump (LDP) increases pressure in the fuel system to 20-30 mbar. The pump membrane is then expanded 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 and the reed contact closes.
4. If reed contact closes within 10 seconds of leak detection time, another test is preformed: 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 recognizes a "small leak" (greater than 1 mm in diameter) or a "large leak".

Leak diagnosis is activated shortly following every engine start. If a malfunction is recognized, a DTC entry follows. The Malfunction Indicator Lamp (MIL) in the instrument cluster will light up if the malfunction is recognized for two subsequent starts. In addition, the diagnosis may be activated using Guided Troubleshooting in the VAS 5051.

Evaporative Emission (EVAP) system, automatic diagnostic leak test

With engine running, the control module performs a diagnostic leak test in certain intervals.

Whether an automatic diagnostic leak test is just being performed can be determined with a connected VAS 5051 tester in measuring value block 071 => Guided Troubleshooting in the VAS 5051.

1. VAS 5051 with VAG 5051/1

Observe safety precautions. See SAFETY PRECAUTIONS .

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

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

Test requirements

1. Parking brake is engaged.
2. Vehicles with manual transmission: Shift lever in idle position.
3. Vehicles with automatic transmission Selector lever in P or N.
4. Engine running at idle
5. Electrical consumers switched off (radiator fan must NOT run during test).
6. A/C switched off.
7. VAS 5051 tester connected and OBD -01 Engine electronics- selected.
8. No DTCs in DTC memory.
9. Intake Air Temperature (IAT) less than 90°C, see display group 004, display field 4
10. Refrigerant temperature less than 95°C, see display group 004, display field 3
11. Throttle valve angle less than 10 ohm % display group 003, display field 3

Display on VAS 5051

Scheme 79

1. In selection -1-, click on the diagnostic function "04 - Basic setting".

Display on VAS 5051

Scheme 80

1. Enter display group

1. Select function "071" in button field -2- for "display group number 071" and press Q button to confirm input.

Display on VAS 5051

Scheme 81

1. Check indication in display field 1. Specification: "Reed closed"

Note. If "Reed cl" (closed) is displayed, continue test. If display indicates "Reed open": briefly open and close fuel filler cap to release pressure from fuel tank. This will close the reed contact.

1. Activate basic setting by pressing button A.
2. Check indication in display field 4. Specification: "Test ON"

The system test lasts several minutes.

1. Check indication in display field 4. Specification: "System OK"

System is sealed, test is terminated.

1. End function "04 - Basic setting" by pressing --> button.

DTC display

If a DTC is recognized during the system test, the DTC evaluation follows.

On VAS 5051 display in display field -4

Scheme 82

1. In case of malfunction: System not OK

1. Check diagnosis evaluation in display field -2-. "Small leak" or "large leak"
2. End function "04 - Basic setting" by pressing --> button.

If the system recognizes a small or large leak

1. See «CHECKING FUEL SUPPLY AND VENTILATION SYSTEMS FOR LEAKS»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .
2. After that, repeat leak test.

Note. The following describes areas in the fuel supply and ventilation systems that should be checked for possible leaks. After making necessary repairs, perform leak test again to make sure that all leaks were successfully repaired.

1. Switch ignition off.
2. Check whether fuel filler cap was completely closed for test.
3. Check seal of fuel filler cap for damage. Replace if necessary.

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

1. Remove 1/3 backrest, left. See «LEFT 1/3 BACKREST, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-except-cabriolet) .
2. Remove left side trim of luggage compartment and protective pan. 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) .

1. Remove cover (arrows).

Vehicles with all-wheel drive

1. Remove rear seat bench. For Cabriolet models, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) . For models other than Cabriolet, see «REAR SEAT BENCH, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/seats/#seats-frames-cabriolet__rear-seat-bench-assembly-overview) .
2. Remove cap for left and right locking flanges (arrows).

Note. Observe installation notes for locking flanges for vehicles with front wheel drive, see INSTALLING and INSTALLING . For vehicles with all wheel drive, see INSTALLING , INSTALLING , INSTALLING or INSTALLING .

1. Check whether seals under connection flanges are OK and union nuts are properly tightened. Also check fuel lines connections.
2. Visually check all wires and hose connections of fuel supply system and replace loose 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 EVAP canister (under cover for EVAP canister) Lines from EVAP system (under right-rear wheel housing liner) Fuel lines to engine

Note. Leaks at lines and components of fuel supply system can sometimes be located using a non-flammable, environmentally sound leak detection spray. For this, initiate leak diagnostic several times in sequence to build pressure in the system. Leaks can be detected via bubbles.

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. 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 initiate leak detection diagnostic. If the 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.

Description

The leak detection threshold has recently changed from 1.0 mm (0.040 in.) to 0.5 mm (0.020 in.). These changes to EPA regulations regarding EVAP system integrity indicated that additional resources for more accurate EVAP system diagnosis are necessary.

The KLI9210 EVAP Tester allows testing using nitrogen to pressurize the EVAP system and a smoke generator or ultrasonic tester to locate the source of EVAP system concerns.

The following procedure will outline general use of the KLI9210 EVAP Tester. It is intended as a guideline, as EVAP systems vary between models.

Test EVAP system using Leak detection pump (LDP) -V144

For vehicles without LDP, proceed to "Perform EVAP tester self-test".

For vehicles with LDP

1. Perform leak test using VAS 5051 Scan Tool and Basic Setting mode. See «EVAPORATIVE EMISSIONS (EVAP) SYSTEM DIAGNOSTIC LEAK TEST, PERFORMING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

If vehicle fails above test ("System not OK")

1. Verify fuel cap is properly closed; repeat test.

If "System OK" after re-test

1. Erase DTC memory (if necessary).
2. Repeat test several times to ensure proper EVAP system operation (remove and re-install fuel cap before each test).
3. Perform quality check and return vehicle to customer.

Note. If the vehicle passes the above EVAP system test, DTCs may be sporadic; the entire EVAP system should be carefully inspected.

If VAS 5051 continues to indicate "System not OK" after re-test, proceed to next step.

Perform EVAP tester self-test

Note. Always perform system self-test of KLI9210 EVAP Tester prior to use to ensure that there are no leaks. Refer to KLI9210 instruction manual for specific instructions.

1. Connect vehicle interface hose to self-test port -1-, ensuring that fitting is finger-tight. Over-tightening will damage fitting.
2. Turn control valve -2- to "Test". Gauge -3- should read 14 + 1 in. of water.

If gauge does not read 14 + 1 in. of water

1. Verify that valve on EVAP tester nitrogen cylinder is open and that cylinder has sufficient pressure before continuing.
2. Turn fine adjust regulator knob (arrow) until gauge reads 14 in. of water; tighten lock nut. NOTE: If gauge still does not read within above range, contact K-Line Customer Service - Technical Support for additional instructions before continuing.
3. Check flow meter -4-. (upper illustration). Meter must indicate no flow.
4. Turn control valve to "Hold" position.
5. Check gauge. Gauge must hold pressure

If gauge leaks down

1. Verify that vehicle interface hose is firmly seated and repeat previous six steps before continuing.

If gauge continues to leak down

1. Use ultrasonic tester (described later) to locate and repair leak before continuing.

Note. If the leak cannot be located or repaired, contact K-Line Customer Service - Technical Support.

Calibrate KLI9210 Tester

Determine vehicle leak threshold

From m.y. 2001: leak threshold 0.020 in.

Scheme 83

1. Attach test hose to appropriate preset port (black arrows).
2. Turn control valve from "Hold" to "Test".
3. Set flow meter flag (white arrow) at indicated value on flow meter.
4. Turn control valve to "Hold"; remove test hose.

Test fuel cap

1. Connect fuel cap tester to hose.
2. Screw fuel cap tightly to cap receiver (arrow).
3. Turn control valve to "Test".
4. Read flow meter on tester.

If no flow is indicated

1. Proceed to "Test LDP for internal leaks".

If flow is indicated

1. Replace fuel cap and re-test.

If new fuel cap shows no flow

1. Repeat Leak Test, with new fuel cap installed, using VAS 5051 and Basic Settings mode. See «EVAPORATIVE EMISSIONS (EVAP) SYSTEM DIAGNOSTIC LEAK TEST, PERFORMING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

If Leak Test shows `System OK"

1. Perform quality check and return vehicle to customer.

Test Leak detection pump (LDP) -V144- for internal leaks

If vehicle is not LDP-equipped, proceed to "Test EVAP system".

1. Clamp off LDP outlet (EVAP side) using Special Tool No. 3094 or equivalent. CAUTION: Clamp only soft rubber lines when isolating a leak. To avoid risk of damage, never clamp hard plastic lines!
2. Repeat Leak Test using VAS 5051 and Basic Setting mode. VAS 5051 should immediately indicate "System OK"
3. Repeat test several times to verify result. If test continues to indicate "System OK", remove clamp and proceed to "Test EVAP System".

If VAS 5051 indicates "System not OK"

1. Replace LDP and repeat test.

If VAS 5051 indicates "System OK" after LDP is replaced and test result is verified

1. Perform quality check and return vehicle to customer.

Test EVAP System

Also, see EVAP CANISTER/LEAK DETECTION SYSTEM, SERVICING (FRONT-AND ALL-WHEEL DRIVE VEHICLES) .

If vehicle is not LDP-equipped

1. Plug or clamp EVAP canister outlet and proceed to step "Continued for all vehicles" (below).

If vehicle is LDP-equipped

1. Plug or clamp LDP inlet (filter side) using Special Tool No. 3094 or equivalent.

Continued for all vehicles

1. Attach fuel cap adapter to filler neck (arrow) and test hose to adapter.
2. Turn control valve from "Hold" to "Test".
3. Allow fuel system to pressurize.

Note. Fuel system pressurization depends on volume of fuel system and amount of fuel in tank.

If fuel system pressurization does not stabilize

1. Verify all fuel system outlets have been sealed before continuing.

Note. Any flow shown on flow meter indicates a leak. Flow before flow meter flag set at vehicle leak standard may indicate a sporadic DTC.

If flow meter on tester registers flow near or above preset pressure

1. Clamp off hose (arrow) leading from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- to intake manifold (pictured: AHA engine in A6).

If flow stops

1. Replace Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- and repeat test before continuing.

If meter indicates no flow after test

1. Perform a quality check and return vehicle to customer.

If flow continues, proceed as follows

Method 1: Locate leak with smoke generator

1. Connect leads from smoke generator to vehicle battery.
2. Use smoke generator trigger to charge fuel system with smoke.
3. Inspect complete EVAP system for escaping smoke.

Scheme 84

General search: tester only

Localized search: tester with extension (on left in illustration)

If leak cannot be located

1. Disconnect and plug or clamp shut EVAP lines to isolate fuel tank, using Special Tool No. 3094 or equivalent, before continuing.

If flow stops

1. Reconnect EVAP lines to search area that was isolated

If leak or source of fuel odor cannot be found

1. Contact Audi Dealer Technician Helpline.

When leak has been located

1. Repair leak and repeat EVAP system test.
2. Perform quality check and return vehicle to customer.

Note. Because leak may be at top of fuel tank, it may not be possible to locate through fuel pump/sending unit access plate. Fuel tank may need to be lowered to locate the leak.

1. VAG 1526A
2. VAG 1527B
3. VAG 1594A
4. VAG 1598/31
5. VAS 5051

Scheme 85

1. Ignition switched on.
2. VAS 5051 tester connected, vehicle On Board Diagnostic (OBD) and-01 Engine electronics- selected.

Checking activation

Display on VAS 5051

Scheme 86

1. In selection -1-, click on the diagnostic function "03 - Output Diagnostic Test Mode (DTM)".

Display on VAS 5051

Scheme 87

A - Actuator test is waiting

Advancing by switching required

1 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80

Press --> button repeatedly, until the following display appears

Display on VAS 5051

Scheme 88

A - Actuator test is waiting

Advancing by switching required

6 - Leak Detection Pump (LDP) tank ventilation system

Click on --> - button

Display on VAS 5051

A - Actuator test is running

Advancing by switch is allowed

1. Leak detection pump (LDP) -V144- will be activated for approximately 1 minute.

Note. The operating noise of the LDP is audible at left rear wheel housing.

1. End function "03 - output Diagnostic Test Mode (DTM)" by pressing --> button.
2. Select "06 - End Output"
3. Switch ignition off.

If Leak Detection Pump (LDP) is not activated (no operating noise audible)

1. Remove Leak detection pump (LDP) -V144-, see «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) and disconnect electrical harness connector.

Scheme 89

1. Connect multimeter for resistance measurement as follows.

LEAK DETECTION PUMP (LDP) -V144-TERMINAL SPECIFICATION CHART

If specified values are not obtained

1. Replace Leak detection pump (LDP) -V144-. See «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

If specified values are obtained

1. Check voltage supply of LDP, see «CHECKING VOLTAGE SUPPLY»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply__checking-voltage-supply) .

Checking voltage supply

Note. Voltage is supplied to the Leak Detection Pump (LDP) via the Fuel Pump (FP) relay.

Test requirement

1. Fuse for Leak Diagnostic Pump (LDP) OK

Scheme 90

1. Connect V.A.G 1527B voltage tester as follows: LEAK DETECTION PUMP WIRING HARNESS GROUND CIRCUIT TEST Wiring harness connector terminal Measure to 3 Engine Ground (GND)
2. Operate starter briefly. LED must light up.

If LED does not light up

1. Check electrical wire connection from terminal 3 to Fuel Pump (FP) relay via fuse for open circuit. See appropriate System Wiring Diagrams article
2. Repair open circuit if necessary.

Scheme 91

1. Connect V.A.G 1527B voltage tester as follows: LEAK DETECTION PUMP WIRING HARNESS OUTPUT CIRCUIT TEST Wiring harness connector terminal Measure to 2 B+
2. Initiate output Diagnostic Test Mode (DTM) and activate Leak Detection Pump (LDP), see «TEST REQUIREMENTS»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .

Display on VAS 5051

Scheme 92

A - Actuator test is running

Advancing by switch is allowed

6 - Leak Detection Pump (LDP) tank ventilation system

1. LED must blink.

If LED does not blink

Scheme 93

Scheme 94

1. End function "03 - Output Diagnostic Test Mode (DTM)" by pressing --> button.
2. Select "06 - End Output"
3. Switch ignition off.
4. Connect V.A.G 1598/31 test box to harness connectors of wiring harness (do not connect ECM). Connect Ground (GND) clip of test box (not visible in illustration) to Ground (GND). For 1.8L Turbo, see «ELECTRICAL TESTING USING VAG1598/31 TEST BOX»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__electrical-testing-using-vag159831-test-box) . For 3.0L V6, see «WIRING AND COMPONENT CHECK WITH TEST BOX VAG 1598/31»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__wiring-and-component-check-with-test) . For 4.2L V8, see «WIRING AND COMPONENT CHECK USING TEST BOX VAG 1598/31»(ref-213322-S25252192212005122900000) . CAUTION: To avoid damaging electronic components, set measuring range before connecting test leads and observe all test requirements.
5. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+: LEAK DETECTION PUMP WIRING HARNESS OPEN/SHORT CIRCUIT TEST Wiring harness connector terminal V.A.G 1598/31 test box socket 2 25
6. Repair open circuit or short circuit if necessary.

If no malfunctions are found, but Leak Diagnostic Pump (LDP) does not function during output Diagnostic Test Mode (DTM)

1. Replace Leak detection pump (LDP) -V144-, see «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply) .
2. Observe safety precautions after re-connecting Engine Control Module (ECM). For 1.8L Turbo, see «PROCEDURE AFTER INTERRUPTION OF VOLTAGE SUPPLY»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__procedure-after-interruption-of-voltage-supply) . For 3.0L V6, see «PROCEDURE AFTER VOLTAGE SUPPLY OPEN CIRCUIT»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk) . For 4.2L V8, see «MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, REPLACING»(ref-213322-S05005981092005122900000) .

Scheme 95

Scheme 96

1. Switch ignition off.
2. Connect V.A.G 1598/31 test box to harness connectors of wiring harness (do not connect ECM). Connect Ground (GND) clip of test box (not visible in illustration) to GND. For 1.8L Turbo, see «ELECTRICAL TESTING USING VAG1598/31 TEST BOX»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__electrical-testing-using-vag159831-test-box) . For 3.0L V6, see «WIRING AND COMPONENT CHECK WITH TEST BOX VAG 1598/31»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__wiring-and-component-check-with-test) . For 4.2L V8, see «WIRING AND COMPONENT CHECK USING TEST BOX VAG 1598/31»(ref-213322-S25252192212005122900000) . CAUTION: To avoid damaging electronic components, set measuring range before connecting test leads and observe all test requirements.
3. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+: LEAK DETECTION PUMP WIRING HARNESS INPUT CIRCUIT TEST Wiring harness connector terminal V.A.G 1598/31 test box Socket 1 80
4. Repair open circuit or short circuit if necessary.
5. Observe safety precautions after reconnecting Engine Control Module (ECM). For 1.8L Turbo, see «PROCEDURE AFTER INTERRUPTION OF VOLTAGE SUPPLY»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-18l-5v-turbo-amb__procedure-after-interruption-of-voltage-supply) . For 3.0L V6, see «PROCEDURE AFTER VOLTAGE SUPPLY OPEN CIRCUIT»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk) . For 4.2L V8, see «MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-, REPLACING»(ref-213322-S05005981092005122900000) .

1. Remove left rear wheel.
2. Remove rear left wheelhousing liner. For Cabriolet models, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-cabriolet) . For models other than Cabriolet, see «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) .
3. Unscrew nuts (arrows).
4. Remove LDP with bracket, disengage harness connector - 3- with ignition off and disconnect.
5. Remove hose connection -4- after pressing release button.
6. Cut through cable tie -1- and disconnect hose -2-.

Installation is reverse of removal, noting the following

1. Secure hose -2- to LDP bracket with cable tie -1-.

Note. Secure all hose connections using hose clamps appropriate for the model type: See Parts Catalog

TIGHTENING TORQUE: LEAK DETECTION PUMP

Accelerator linkage, servicing

The following list pertains to see scheme 413.

1. Accelerator pedal module With Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185- Removing and installing, see «ACCELERATOR PEDAL MODULE WITH ACCELERATOR POSITION SENDER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/fuel-system/#fuel-supply)
2. 10 Nm
3. 6 pin connector
4. 10 Nm

1. Remove storage compartment on driver's side: For Cabriolet models, see «DRIVER'S STORAGE COMPARTMENT (VEHICLES WITH AND WITHOUT KNEE BOLSTER), ASSEMBLY OVERVIEW»(ref-197209-S29048734852005101300000) . For models other than Cabriolet, see «DRIVER'S STORAGE COMPARTMENT (VEHICLES WITH AND WITHOUT KNEE BOLSTER), ASSEMBLY OVERVIEW»(ref-197209-S29048734852005101300000) .
2. Disconnect 6-pin connector -2-.
3. Remove bolts -1- and -3-.
4. Remove accelerator pedal module.

Installation is performed in the reverse order.

TIGHTENING TORQUE: ACCELERATOR PEDAL MODULE

Vehicles with automatic transmission

On vehicles with automatic transmission the kickdown function must be programmed into the control unit if the accelerator position sender or the engine control unit is replaced.

Requirements

1. Vehicle diagnostic, testing and information system VAG 1551 connected, vehicle On Board Diagnostic (OBD) mode function "01 - engine electronics" selected.
2. No malfunctions stored in DTC memory
3. Engine not running; ignition switched on.

1. Initiate basic setting, display group 063.

Display on VAS 5051

Scheme 97

1. Check display in display zones -3- and -4-.

Indicated on display: operate kickdown

1. Press accelerator pedal all the way down past the kickdown point and hold in position.

Indicated on display: kickdown ADP runs

1. Check the readout in display zones -3- and -4

Indicated on display: kickdown ADP OK

Note. If "Kickdown ERROR" is indicated: check DTC 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 adaptation process is finished. Interrupt function "04 - Basic setting" by pressing the --> button and restart adaptation.

1. Terminate operation "04 - Basic setting" by pressing the --> button.
2. Select operation "06 - End output".
3. Switch off ignition and disconnect the diagnostic connector.

See also:
• EMERGENCY BATTERY, SWITCHING OFF/ON
• BATTERY DISCONNECT PRECAUTIONS
• LEFT 1/3 BACKREST, REMOVING AND INSTALLING
• SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW
• WHEEL HOUSING LINER
• WHEEL HOUSING LINER
• EXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLATION
• EXHAUST SYSTEM, SERVICING
• SUSPENSION - REAR
• SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND RESIDUAL PRESSURE, CHECKING
• FUEL PRESSURE REGULATOR AND HOLDING PRESSURE (VEHICLES UP TO 06.03), CHECKING
• CHECKING FUEL PRESSURE REGULATOR -- VEHICLES
• SYSTEM PRESSURE AND HOLDING PRESSURE (VEHICLES AS OF 07.03), CHECKING
• REAR SEAT BENCH, ASSEMBLY OVERVIEW
• DRIVESHAFT & UNIVERSAL JOINTS - 01V (AWD TRANSAXLE)
• FUEL SYSTEM, BLEEDING
• ELECTRICAL TESTING USING VAG1598/31 TEST BOX
• WIRING AND COMPONENT CHECK WITH TEST BOX VAG 1598/31
• PROCEDURE AFTER INTERRUPTION OF VOLTAGE SUPPLY
• PROCEDURE AFTER VOLTAGE SUPPLY OPEN CIRCUIT
• SAFETY PRECAUTIONS
• RULES FOR CLEANLINESS
• FUEL SUPPLY SYSTEM, SERVICING GUIDELINES
• INSTALLATION POSITION OF GROUND CONNECTION
• ELECTRICAL TEST FOR FUEL TANK LOCK SWITCH -F314
• POSITION OF GROUND CONNECTION
• SUCTION JET PUMP, FUNCTION
• EVAP CANISTER, REMOVING AND INSTALLING
• INSTALLATION POSITION OF T-PIECE
• INSTALLATION LOCATION OF SEPARATING POINT
• EVAP CANISTER/LEAK DETECTION SYSTEM, SERVICING (FRONT-AND ALL-WHEEL DRIVE VEHICLES)
• CHECKING VOLTAGE SUPPLY