Fuel Supply System Audi A4 B7

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

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

When removing and installing components from a full or partially full fuel tanks, note the following

1. The fuel tank may only be partially full. How much fuel can remain in the fuel tank may be read in the respective work description. Drain fuel tank if necessary. Procedure: Vehicles with front wheel drive up to 06.03 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-tank-draining) , Vehicles with front wheel drive from 07.03 to 10.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with front wheel drive as of 11.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with all wheel drive up to 06.03 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with all wheel drive from 07.03 to 10.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with all wheel drive as of 11.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .
2. Before starting work, switch on exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m 3 /h can be used.
3. Prevent fuel from contacting skin! Wear fuel-resistant gloves!

Note the following when removing and installing fuel tank

1. Fuel tank must be empty for weight reasons. Drain fuel tank if necessary. Procedure: Vehicles with front wheel drive up to 06.03 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-tank-draining) , Vehicles with front wheel drive from 07.03 to 10.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with front wheel drive as of 11.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with all wheel drive up to 06.03 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with all wheel drive from 07.03 to 10.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , Vehicles with all wheel drive as of 11.04 --> «Fuel tank, draining»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Rules for cleanliness

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

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover them. Do not use fluffy cloths!
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpackaged (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Fuel tank with attachments, assembly overview

Note. The fuel system shown in illustration is for vehicles with 6-cyl. engine.

Scheme 167

1 - Fuel supply line

1. From fuel filter
2. To engine
3. Do not kink
4. To disconnect, press release button on connection piece

2 - Fuel return line

1. From engine
2. Do not kink
3. To disconnect, press release button on connection piece
4. Clipped in on fuel tank

3 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. Do not kink
3. To disconnect, press release button on connection piece
4. Clipped in on fuel tank

4 - Electrical harness connector

1. For Fuel Tank Lock Switch F314
2. Checking electrical --> «Fuel Tank Lock Switch F314 , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-tank-lock-switch-f314)

5 - 23 Nm

6 - Overflow hose

1. Engage in wheelhousing

7 - Rubber gasket

8 - Circlip

9 - Oil seal

1. Replace if damaged

10 - Filler cap

11 - Ground (GND) connection

1. For discharging electrostatic charge
2. Installed position/check requirements «Installation position of Ground (GND) connection»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__installation-position-of-ground-gnd-connection)
3. After installing, check electrical connection of metal ring at fuel filler tube to a bare area of chassis using Ohm meter - Specified value: approx. 0ohms

12 - Ventilation line

13 - Ventilation line

1. From gravity valve to EVAP canister
2. To remove, press release ring on EVAP canister

14 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. To remove, press release ring on EVAP canister
3. Clipped in on fuel tank

15 - Fuel tank

1. Removing and installing --> «Fuel tank with attachments, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-tank-with-attachments-removing-and)

16 - Heat shield

1. For fuel tank

17 - 2 Nm

18 - Heat shield

1. For fuel tank

19 - 2 Nm

20 - Spreader clip

21 - Securing strap

1. Note different lengths

22 - 23 Nm

Scheme 168

1. Route Ground (GND) connection as shown in illustration.
2. Engage Ground (GND) connection contact - 1 - into opening on fuel tank - 4 -.
3. Make sure that Ground (GND) connection connector - 3 - is secured at metal ring - 2 - of fuel filler tube.

Fuel tank, draining

Special tools, testers and auxiliary items required

Scheme 169

Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

Scheme 170

1. Push cover over battery toward the right - arrow 1 - and remove it upward - arrow 2 -.

Scheme 171

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Scheme 172

1. Pull cone piece - 2 - from shaft piece - 1 - of fuel siphoning device VAS 5190.
2. Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,465 mm from end of suction hose.

Scheme 173

1. Remove fuel filler cap from fuel filler tube.
2. Screw shaft piece - 1 - of fuel extraction unit VAS 5190 on to fuel filler tube of fuel tank.
3. Push suction hose as far into fuel tank until the mark applied earlier - arrow - is positioned on shaft piece.

Scheme 174

Note. If using a siphoning device without a shaft piece, proceed basically in the same manner. In this case, apply a mark - arrow - using insulating tape on hose at length - a - = 1,400 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube. If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube.
2. Carefully pull out suction hose.
3. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Fuel tank with attachments, removing and installing

Special tools, testers and auxiliary items required

Scheme 175

Engine/transmission jack V.A.G 1383 A

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler cap briefly and then close again.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

Scheme 176

1. Unbolt cover for locking flange - arrows - in luggage compartment.

Scheme 177

1. Disconnect electrical harness connector - 1 - at locking flange.
2. Disconnect electrical connector - 2 -.

Vehicles with hose connection

Scheme 178

1. Disconnect ventilation line - 1 -.

Vehicles with connection coupling

Scheme 179

1. Disconnect ventilation line - 1 -. Do this by pressing releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line off - arrow B -.

All models

Scheme 180

1. Open tank flap and clean area around fuel filler tube.

Note. Do not remove fuel cap.

1. Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.

Scheme 181

1. Remove right rear wheel.
2. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Disconnect ventilation line - 2 - from fuel filler tube.
4. Remove bolts - 1 - for fuel filler tube.

Scheme 182

1. Remove EVAP canister cover at bottom of spare wheel well - arrows -.

Scheme 183

1. Remove ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Unclip ventilation lines at top from bracket - arrow -.

Scheme 184

1. Remove vehicle floor cover - arrows -.

Scheme 185

1. Remove covers - 1 - and - 2 - for vehicle floor.
2. Remove rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .

1. Remove rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 186

1. Disconnect right parking brake cable at front of fuel tank at the areas indicated with - arrows -.

Fuel system with return line

Scheme 187

1. Disconnect fuel supply line - 1 - from fuel filter, by pressing release buttons. Catch escaping fuel.
2. Disconnect fuel return line - 3 - and ventilation line - 2 - at connection point, by pressing release buttons.

Fuel system without return line

Scheme 188

1. Separate ventilation line - 2 - and fuel line - 1 - from right front of fuel tank, by pressing release buttons.

All models

1. Place engine/transmission jack V.A.G 1383 A under fuel tank for support.

Scheme 189

1. Remove bolts - 1 to 7 -.
2. Lower fuel tank using engine/transmission jack V.A.G 1383 A.

Installing

Installation is in reverse order of removal. Note the following

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

Scheme 190

1. Make sure fuel and ventilation lines are properly clipped to fuel tank - arrows -.
2. Check if Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
3. Check installation position of Ground (GND) connection

1. The connector - 3 - must be securely attached to metal ring - 2 -.
2. The contact - 1 - must be hooked into fuel tank - 4 -.

1. Position fuel tank with mounting straps to vehicle floor using engine/transmission jack V.A.G 1383 A.
2. Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of the body.

1. First tighten fuel tank at securing points - 2, 5, 3, 4 - and then at - 1, 6, 7 -.
2. Fasten fuel filler tube.

1. Install rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
3. Install right rear wheel housing liner, by fastening bolts for fuel filler tube --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
4. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Fuel delivery unit and fuel level sensor, assembly overview

Note. Fuel delivery unit shown in illustration is for vehicles with 6-cyl. engine.

Scheme 191

1 - Fuel Level Sensor G

1. Resistance values, checking --> «Fuel Level Sensor G , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-g-checking)
2. Removing and installing --> «Fuel Level Sensor G , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-g-removing)

2 - Fuel delivery unit

1. Fuel pump electrical, checking --> «Fuel pump electrical, checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-pump-electrical-checking)
2. Checking residual pressure --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF
3. Removing and installing --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-delivery-unit-removing-and-installing)

3 - Seal

1. Always replace
2. Install dry

4 - Fuel return line

1. Mark before removing
2. To disconnect, press release button on connection piece
3. Do not kink
4. Note direction of arrow (fuel supply or return) on locking flange when installing

1. Clipped in on fuel tank

5 - Fuel supply line

1. Mark before removing
2. To disconnect, press release button on connection piece
3. Do not kink
4. Note direction of arrow (fuel supply or return) on locking flange when installing

1. Clipped in on fuel tank

6 - Electrical harness connector

1. For Fuel level sensor G
2. For Transfer Fuel Pump (FP) G6

7 - Union nut, 80 Nm

1. Use ring nut wrench 3217 for removal and installation

8 - Suction jet pipe

1. To disconnect, press release button on connection piece

9 - Suction jet pump

Scheme 192

Special tools, testers and auxiliary items required

1. Remote control connection V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Portable multimeter V.A.G 1526 B
3. Connector test set V.A.G 1594 C

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuse on fuse panel S228 (position 28) OK.

Scheme 193

1. Fuel Pump (FP) Relay J17 - arrow - at position 1 in 9-socket relay carrier behind driver side storage compartment is OK.
2. Fuel filter OK
3. Ignition switched off.

Test sequence

1. Open fuse box cover on left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

Scheme 194

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Press remote control switch.

1. Running noise of pump must be audible.

Note. Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt locking flange cover in luggage compartment - arrows -.

1. Disconnect electrical harness connector - 1 - at locking flange.

Note. Ignore - 2 -.

Scheme 195

1. Connect hand multimeter V.A.G 1526 B between terminal - 1 - and - 4 - for voltage measurement.
2. Press switch on remote control.

1. Specification: approx. battery voltage.

If specification is not obtained

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

Scheme 196

If specified value is obtained, although no running-noise can be heard at pump

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-delivery-unit-removing-and-installing) .
2. Check if electrical wiring between flange and fuel pump is connected and has continuity.

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

1. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__installing) .

Delivery rate of fuel pump, checking (vehicles with 1.8L turbo engine)

Special tools, testers and auxiliary items required

Scheme 197

1. Adapter V.A.G 1318/17-1 from adapter set V.A.G 1318/17

Scheme 198

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK, checking --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery positive (+).
3. Remove fuel filler cap from fuel filler tube.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt locking flange cover - arrows - in luggage compartment.

Scheme 199

1. Disconnect fuel return line - 2 - by pressing release buttons.

Note. Ignore - 1 -.

Scheme 200

1. Connect adapter V.A.G 1318/17-1 to disconnected fuel return line and hold it in a measuring container.
2. Press switch on remote control for 15 seconds.

Scheme 201

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Assembly is in reverse order of removal. Note the following

1. Install fuel return line.

Delivery rate of fuel pump, checking (vehicles with 6-cyl. MPI-engine)

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK, checking --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery positive (+).
3. Remove fuel filler cap from fuel filler tube.

1. Disconnect fuel return hose from line connection on fuel rail line.

Scheme 202

1. Connect extension hose - arrow - onto fuel rail and hold it in a measuring container.
2. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Assembly is in reverse order of removal. Note the following

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

1. Install fuel return hose.

Fuel delivery unit, removing and installing

Special tools, testers and auxiliary items required

Scheme 203

1. Ring nut wrench 3217

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt locking flange cover in luggage compartment - arrows -.

1. Disconnect electrical harness connector - 1 - at locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

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

1. Pull both lines from locking flange, by pressing release buttons.

Vehicles with 1.8L Turbo engine

1. Also separate ventilation line to fuel filter at locking flange, by pressing release buttons.

All models

Scheme 204

1. Remove union nut using Ring nut wrench 3217.

Scheme 205

1. Lift fuel delivery unit slightly out of fuel tank opening and remove seal.
2. If fuel delivery unit is still inserted in fuel tank, slide locking flange slightly to side.
3. Reach through gap between locking flange and installation opening in fuel tank and release suction jet pump - 1 -.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown.

Scheme 206

1. Lift suction jet pump - 1 - upward with suction jet pipe - 2 - still connected.
2. Disconnect suction jet line from suction jet pump by pressing release button.
3. Remove suction jet pump.
4. Remove fuel delivery unit.

Note. When removing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor G. Be aware that fuel is still in the fuel delivery unit.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace seal. When installing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G. Make sure fuel hose is seated securely.

1. Insert fuel delivery unit into fuel tank.

1. Connect suction jet line - 2 - to connection for suction jet pump - 1 -.

1. Clip in suction jet pump - 1 - on fuel delivery unit. To do so, insert hand into gap between locking flange and installation opening of fuel tank.

1. Suction jet pump must engage audibly.

1. Verify that the suction jet pump is securely engaged.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown.

Scheme 207

1. Install new locking flange seal dry.
2. Press locking flange down against spring pressure and bring it into installation position.

1. Marking - 2 - on locking flange must align with marking - 1 - on fuel tank.

1. Tighten union nut for locking flange.

1. Install fuel supply line - 1 - and fuel return line - 2 - according to marking.

Vehicles with 1.8L Turbo engine

1. Also, install ventilation line to fuel filter at locking flange.

All models

1. Connect electrical harness connector.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Fuel Level Sensor G , checking

Special tools, testers and auxiliary items required

Scheme 208

1. Portable multimeter V.A.G 1526 B

Scheme 209

1. Connector test set V.A.G 1594 C

Test sequence

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt locking flange cover in luggage compartment - arrows -.

1. Disconnect electrical harness connector - 1 - at locking flange.

Note. Ignore - 2 -.

Scheme 210

1. Connect hand multimeter V.A.G 1526 B between terminal - 2 - and - 3 - for resistance measurement.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values for "tank full" or "tank empty" , the fuel delivery unit must be removed --> Fuel delivery unit, removing and installing and the sensor float must be placed in upper or lower end position. With fuel level sensor G removed, the following values are obtained because of the greater deflection of the floater arm

Fuel Level Sensor G , removing and installing

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-delivery-unit-removing-and-installing) .

Scheme 211

1. Disengage electrical connectors - 1 - and - 2 - and disconnect them.
2. Pry on retaining tabs - 3 - and - 4 - with a screwdriver and pull fuel level sensor G off downward - arrow -.

Installing

Installation is in reverse order of removal. Note the following

1. Insert fuel level sensor G into guides on fuel delivery unit and push up until it engages.
2. Connect electrical connections and check that they are securely engaged.
3. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__installing) .

Fuel Tank Lock Switch F314 , checking

The Fuel Tank Lock Switch F314 consists of a reed contact on fuel filler tube and a fuel tank cap with an embedded magnet. If fuel tank cap is not fully screwed on, the reed contact switches on an indicator in the instrument cluster.

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 B

1. Connector test set V.A.G 1594 C

Test sequence

Scheme 212

1. If indicator is lit, check the following points in order

1. Fuel tank cap is completely screwed on.
2. Correct fuel tank cap (Identification: Threads are gray in color).
3. Switch - arrow - at fuel filler tube is fully inserted.
4. Electrical switch is faulty.

1. Wiring connection to instrument cluster is faulty (check according to schematics).

Fuel Tank Lock Switch F314 , checking electrical

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt locking flange cover in luggage compartment - arrows -.

1. Disconnect electrical connector - 2 -.

Note. Ignore - 1 -.

Scheme 213

1. Connect hand multimeter V.A.G 1526 B between terminal - 1 - and - 2 - for resistance measurement.

If specifications are not obtained

1. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Replace Fuel Tank Lock Switch F314 - arrow - , by unclipping and clipping in switch and electrical wiring at fuel filler tube.

Scheme 214

1 - Fuel line

1. From fuel filter
2. To engine
3. Do not kink
4. To disconnect, press release button on connection piece

2 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. Do not kink
3. To disconnect, press release button on connection piece
4. Clipped in on fuel tank

3 - Electrical harness connector

1. For Fuel Tank Lock Switch F314
2. Checking electrical --> «Fuel Tank Lock Switch F314 , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

4 - 2 Nm

5 - Heat shield

1. For fuel delivery connection

6 - 23 Nm

7 - Overflow hose

1. Engage in wheelhousing

8 - Rubber pan

9 - Circlip

10 - Oil seal

1. Replace if damaged

11 - Cap

12 - Ground (GND) connection

1. For discharging electrostatic charge
2. Installed position/check requirements «Installation position of Ground (GND) connection»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
3. After installing, check electrical connection of metal ring at fuel filler tube to a bare area of chassis using Ohm meter - Specified value: approx. 0ohms

13 - Ventilation line

14 - Ventilation line

1. From gravity valve to EVAP canister
2. To remove, press release ring on EVAP canister

15 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. To remove, press release ring on EVAP canister
3. Clipped in on fuel tank

16 - Fuel tank

1. Removing and installing --> «Fuel tank with attachments, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

17 - Heat shield

1. For fuel tank

18 - 2 Nm

19 - Heat shield

1. For fuel tank

20 - 2 Nm

21 - Spreader clip

22 - Securing strap

1. Observe varying lengths

23 - 23 Nm

Scheme 215

1. Route Ground (GND) connection as shown in .
2. First, hook Ground (GND) contact - 1 - connection into securing hole on fuel tank - 5 - and then press in spacer bushing - 2 -.
3. Make sure connector of Ground (GND) connection - 4 - fits securely at metal ring - 3 - of fuel filler tube.

Special tools, testers and auxiliary items required

1. Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

1. Pull cone piece - 2 - from shaft end - 1 - of fuel siphoning device VAS 5190.
2. Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,465 mm from end of suction hose.
3. Remove fuel filler cap from fuel filler tube.

1. Screw shaft end - 1 - of fuel siphoning device VAS 5190 on to fuel filler tube of fuel tank.
2. Push suction hose as far into fuel tank until the mark applied earlier - arrow - is positioned on shaft end.

Note. If using a siphoning device without shaft end, proceed basically in the same manner. In this case, apply a mark - arrow - using insulating tape on hose at length - a - = 1,400 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube. If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube.
2. Carefully pull out suction hose.
3. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler cap briefly and then close again.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward the right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

Scheme 216

1. Disconnect electrical harness connector - 1 - at locking flange.
2. Disconnect electrical connector - 2 -.

1. Separate ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approx. 2 mm in direction - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Open tank flap and clean the area around fuel filler tube.

Note. Do not remove fuel cap.

1. Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward the inside.
2. Remove right rear wheel.
3. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Scheme 217

1. Remove ventilation line - 2 - from fuel filler tube by pressing release buttons.
2. Remove bolts - 1 - for fuel filler tube.

1. Remove EVAP canister cover at bottom of spare wheel well - arrows -.

1. Remove ventilation lines - 1 - and - 2 -. Do this by pressing the releasing ring - 3 - in direction of - arrow A - and simultaneously pulling off ventilation line - arrow B -.
2. Unclip ventilation lines - A - at top from bracket - arrow -.

1. Remove cover for vehicle floor - arrows -.

1. Remove covers - 1 - and - 2 - for vehicle floor.
2. Remove rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .

1. Remove rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Disconnect right parking brake cable at front of fuel tank at areas indicated with - arrows -.

1. Disconnect ventilation line - 2 - and fuel line - 1 - from right front of fuel tank, by pressing release buttons.
2. Place engine/transmission jack V.A.G 1383 A under fuel tank for support.

1. Remove bolts - 1 through 7 -.
2. Lower fuel tank using engine/transmission jack V.A.G 1383 A.

Installing

Installation is in reverse order of removal. Note the following

Scheme 218

1. Make sure fuel and ventilation lines are properly clipped to fuel tank - arrows -.
2. Check if Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
3. Check installation position of Ground (GND) connection

1. Connector - 4 - must be securely attached to metal ring - 3 -.
2. Contact - 1 - must be attached into fuel tank - 5 - and be secured with spacer bushing - 2 -.

1. Position fuel tank with mounting straps to vehicle floor using engine/transmission jack V.A.G 1383 A.
2. Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of the body.

1. First tighten fuel tank at securing points - 2, 5, 3, 4 - and then at - 1, 6, 7 -.
2. Fasten fuel filler tube.

1. Install rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
3. Install right rear wheel housing liner, thereby fastening bolt for fuel filler tube --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
4. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Scheme 219

1 - Fuel Level Sensor G

1. Resistance values, checking --> «Fuel Level Sensor G , testing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-g-testing)
2. Removing and installing --> «Fuel Level Sensor G , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

2 - Fuel delivery unit

1. Fuel pump electrical, checking --> «Fuel pump electrical, checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
2. Checking residual pressure --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF
3. Removing and installing --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

3 - Oil seal

1. Replace
2. Install dry

4 - Fuel return line

1. From fuel filter
2. Mark before removing
3. To disconnect, press release button on connection piece
4. Do not kink

1. Note direction of arrow (fuel supply or return) on locking flange when installing
2. Clipped in on fuel tank

5 - Ventilation line

1. From fuel pressure regulator in fuel filter
2. To disconnect, press release button on connection piece
3. Do not kink
4. Clipped in on fuel tank

6 - Fuel supply line

1. To fuel filter
2. Mark before removing
3. To disconnect, press release button on connection piece
4. Do not kink

1. Note direction of arrow (fuel supply or return) on locking flange when installing
2. Clipped in on fuel tank

7 - Electrical harness connector

1. For Fuel level sensor G
2. For Transfer Fuel Pump (FP) G6

8 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

9 - Suction jet pipe

1. To disconnect, press release button on connection piece

10 - Suction jet pump

Fuel pump electrical, checking

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
2. Portable multimeter V.A.G 1526 B
3. Connector test set V.A.G 1594 C

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuse on fuse panel S228 (position 28) OK.

1. Fuel Pump (FP) Relay J17 - arrow - at position 1 in 9-socket relay carrier behind driver side storage compartment is OK.
2. Fuel filter OK
3. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Press switch on remote control.

1. Running noise of pump must be audible.

Note. Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt locking flange cover in luggage compartment - arrows -.

1. Disconnect electrical harness connector - 1 - at locking flange.

Note. Ignore - 2 -.

1. Connect hand multimeter V.A.G 1526 B between terminal - 1 - and - 4 - for voltage measurement.
2. Press switch on remote control.

1. Specification: approx. battery voltage.

If specification is not obtained

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

If specified value is obtained, although no running-noise can be heard at pump

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .
2. Check if electrical wiring between flange and fuel pump is connected and has continuity.

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

1. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Delivery rate of fuel pump, checking (vehicles with 1.8L Turbo engine and 6-cyl. MPI-engine)

Special tools, testers and auxiliary items required

1. Adapter V.A.G 1318/17-1 from adapter set V.A.G 1318/17

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK, checking --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Remove fuel filler cap from fuel filler tube.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward the right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

Scheme 220

1. Disconnect fuel return line - arrow - by pressing release buttons.

1. Connect adapter V.A.G 1318/17-1 to disconnected fuel line and hold it in a measuring container.
2. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Assembly is in reverse order of removal. Note the following

1. Install fuel return line.

Special tools, testers and auxiliary items required

Scheme 221

1. Wrench T10202

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward the right rear seat backrest of, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Disconnect electrical harness connector - 1 - at locking flange.
2. Disconnect electrical harness connector - 2 - and lay it aside.

Scheme 222

1. Mark fuel supply line - 1 - and fuel return line - 3 -.

1. Pull both lines from locking flange, by pressing release buttons.
2. Disconnect ventilation line - 2 - by pressing release buttons.

Scheme 223

1. Remove locking ring using wrench T10202.
2. Lift fuel delivery unit slightly out of the fuel tank opening and remove seal.
3. If fuel delivery unit is still inserted in fuel tank, slide fuel delivery unit with locking flange slightly to the side.

1. Reach through gap between locking flange and installation opening in fuel tank and release suction jet pump - 1 -.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown.

1. Pull suction jet pump - 1 - upward with suction jet pipe - 2 - still connected.
2. Disconnect suction jet pipe from suction jet pump by pressing release button.
3. Remove suction jet pump.
4. Remove fuel delivery unit.

Note. When removing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor G. Be aware that fuel is still in the fuel delivery unit.

Installation is in reverse order of removal. Note the following

Note. Replace seal. When installing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G. Make sure fuel hose is seated securely.

1. Insert fuel delivery unit into fuel tank.

1. Connect suction jet pipe - 2 - to connection for suction jet pump - 1 -.

1. Clip in suction jet pump - 1 - on fuel delivery unit. To do so, insert hand into gap between locking flange and installation opening of fuel tank.

1. Suction jet pump must engage audibly.

1. Verify that the suction jet pump is securely engaged.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown.

1. Install new locking flange seal dry.
2. Press locking flange down against spring pressure and bring it into installation position.

Scheme 224

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.

1. Install fuel supply line - 1 - and fuel return line - 3 - according to the marking.
2. Install ventilation line - 2 -.
3. Connect electrical harness connector.
4. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Fuel Level Sensor G , testing

Special tools, testers and auxiliary items required

Scheme 225

1. Portable multimeter V.A.G 1526 C

1. Connector test set V.A.G 1594 C

Test sequence

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Remove locking flange cover in luggage compartment - arrows -.

1. Disconnect electrical harness connector - 1 - at locking flange.

Note. Ignore - 2 -.

Scheme 226

1. Connect hand multimeter V.A.G 1526 B between terminal - 2 - and - 3 - for resistance measurement.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty" , the fuel delivery unit must be removed --> Fuel delivery unit, removing and installing and the floater of the sensor must be placed in upper or lower end position. With fuel level sensor G removed, the following values are obtained because of the greater deflection of the floater arm

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

1. Disengage electrical connector retaining tabs - 1 - and - 2 - and disconnect them.
2. Pry on retaining tabs - 3 - and - 4 - with a screwdriver and pull fuel level sensor G off downward - arrow -.

Installing

Installation is in reverse order of removal. Note the following

1. Insert fuel level sensor G into guides on fuel delivery unit and push up until it engages.
2. Connect electrical connections and check that they are securely engaged.
3. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

The Fuel Tank Lock Switch F314 consists of a reed contact on fuel filler tube and a fuel tank cap with an embedded magnet. If fuel tank cap is not fully screwed on, the reed contact switches on an indicator in instrument cluster.

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 C

1. Connector test set V.A.G 1594 C

1. If indicator is lit, check the following points in order

1. Fuel tank cap is completely screwed on.
2. Correct fuel tank cap (Identification: Threads are gray in color).

Scheme 227

1. Switch - arrow - at fuel filler tube is fully inserted.
2. Electrical malfunction in switch.
3. Wiring connection to instrument cluster is faulty (check according to schematics).

Fuel Tank Lock Switch F314 , checking electrical

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Disconnect electrical connector - 2 -.

Note. Ignore - 1 -.

1. Connect hand multimeter V.A.G 1526 between terminal - 1 - and - 2 - for resistance measurement.

If specifications are not obtained

1. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Replace Fuel Tank Lock Switch F314 - arrow - , thereby unclipping and clipping in switch and electrical wiring at fuel filler tube.

Scheme 228

1 - Fuel line

1. From fuel filter
2. To engine
3. Do not kink
4. To disconnect, press release button on connection piece

2 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. Do not kink
3. To disconnect, press release button on connection piece
4. Clipped in on fuel tank

3 - 2 Nm

4 - Tire protection shield

1. For fuel delivery connection

5 - 23 Nm

6 - Overflow hose

1. Engage in wheelhousing

7 - Rubber gasket

8 - Circlip

9 - Seal

1. Replace if damaged

10 - Cap

11 - Ground (GND) connection

1. For discharging electrostatic charge
2. Installed position/check requirements «Installation position of Ground (GND) connection»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
3. After installing, check electrical connection of metal ring at fuel filler tube to a bare area of chassis using Ohm meter - Specified value: approx. 0 ohms

12 - Ventilation line

13 - Ventilation line

1. From gravity valve to EVAP canister
2. To remove, press release ring on EVAP canister

14 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. To remove, press release ring on EVAP canister
3. Clipped in on fuel tank

15 - Fuel tank

1. Removing and installing --> «Fuel tank with attachments, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

16 - Heat shield

1. For fuel tank

17 - 2 Nm

18 - Heat shield

1. For fuel tank

19 - 2 Nm

20 - Spreader clip

21 - Securing strap

1. Observe varying lengths

22 - 23 Nm

Installation position of Ground (GND) connection

1. Route Ground (GND) connection as shown in .
2. First hook Ground (GND) connection contact - 1 - into securing hole on fuel tank - 5 - and then press in spacer bushing - 2 -.
3. Make sure Ground (GND) connector connection - 4 - fits securely at metal ring - 3 - of fuel filler tube.

Special tools, testers and auxiliary items required

1. Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

1. Pull cone piece - 2 - from shaft end - 1 - of fuel extraction unit VAS 5190.
2. Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,465 mm from end of suction hose.

1. Remove fuel filler cap from fuel filler tube.
2. Screw shaft piece - 1 - of fuel extraction unit VAS 5190 on to fuel filler tube of fuel tank.
3. Push suction hose as far into fuel tank until the mark applied earlier - arrow - is positioned on shaft end.

Note. If using a siphoning device without shaft end, proceed basically in the same manner.

1. In this case, apply a mark - arrow - using insulating tape on hose at length - a - = 1,400 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
2. If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube.
2. Carefully pull out suction hose.
3. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. All
3. Open fuel filler flap briefly and then close again.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt locking flange cover in luggage compartment - arrows -.

Scheme 229

1. Disconnect electrical harness connector - arrow - at locking flange.

1. Disconnect ventilation line - 1 -. Do this by pressing releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Open tank flap and clean area around fuel filler tube.

Note. Do not remove fuel cap.

1. Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.

1. Remove right rear wheel.
2. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Pull ventilation line - 2 - off from fuel filler tube by pressing release buttons.
4. Remove bolts - 1 - for fuel filler tube.

1. Remove EVAP canister cover at bottom of spare wheel well - arrows -.

1. Disconnect ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Unclip ventilation lines - A - at top from bracket - arrow -.

1. Remove cover for vehicle floor - arrows -.

1. Remove covers - 1 - and - 2 - for vehicle floor.
2. Remove rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .

1. Remove rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Disconnect right parking brake cable at front of fuel tank at areas indicated with - arrows -.

Scheme 230

1. Separate ventilation line - 1 - and fuel line - 2 - from right of fuel tank, by pressing release buttons.
2. Place engine/transmission jack V.A.G 1383 A under fuel tank for support.

1. Remove bolts - 1 to 7 -.
2. Lower fuel tank using engine/transmission jack V.A.G 1383 A.

Installing

Installation is in reverse order of removal. Note the following

1. Make sure fuel and ventilation lines are properly clipped to fuel tank - arrows -.
2. Check if ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
3. Check installation position of ground (GND) connection

1. Connector - 4 - must be securely attached to metal ring - 3 -.
2. Contact - 1 - must be attached into fuel tank - 5 - and be secured with spacer bushing - 2 -.

1. Position fuel tank with mounting straps to vehicle floor using engine/transmission jack V.A.G 1383 A.
2. Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of the body.

1. First tighten fuel tank at securing points - 2, 5, 3, 4 - and then at - 1, 6, 7 -.
2. Fasten fuel filler tube.

1. Install rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
3. Install right rear wheel housing liner, by fastening screws for fuel filler tube --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
4. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Scheme 231

1 - Fuel delivery unit

1. Fuel pump electrical, checking --> «Fuel pump electrical, checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
2. Removing and installing --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

2 - Fuel Level Sensor G

1. Resistance values, checking --> «Fuel level sensor G , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
2. Removing and installing --> «Fuel level sensor G , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

3 - Suction jet pipe

1. To disconnect, press release button on connection piece

4 - Seal

1. Replace
2. Install dry

5 - Fuel return line

1. From fuel filter
2. Mark before removing
3. To disconnect, press release button on connection piece
4. Do not kink

1. Note direction of arrow (fuel supply or return) on locking flange when installing
2. Clipped in on fuel tank

6 - Fuel supply line

1. To fuel filter
2. Mark before removing
3. To disconnect, press release button on connection piece
4. Do not kink

1. Note direction of arrow (fuel supply or return) on locking flange when installing
2. Clipped in on fuel tank

7 - Electrical harness connector

1. For Fuel level sensor G
2. For Transfer Fuel Pump (FP) G6

8 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

9 - Suction jet pump

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
2. Portable multimeter V.A.G 1526 B
3. Connector test set V.A.G 1594 C

Test conditions

1. Battery voltage at least 12.5 V.

Scheme 232

1. Fuse on fuse panel S228 (position 28) OK.

1. Vehicles with MPI engine: Fuel Pump (FP) Relay J17 - arrow - at position 1 in 9-socket relay carrier behind driver side storage compartment is OK.

Scheme 233

1. Vehicles with FSI engine: Fuel Pump (FP) Control Module J538 OK; check --> «Fuel Pump (FP) Control Module J538 , checking (vehicles with FSI engine)»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .
2. Fuel filter OK
3. Ignition switched off.

Test sequence

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Disconnect electrical harness connector - arrow - at locking flange.

Scheme 234

1. Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 1 - using an adapter cable from connector test set V.A.G 1594 C.
2. Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit - arrow -.
3. Connect contact - 4 - to vehicle Ground (GND) using a jumper cable from connector test set V.A.G 1594 C.
4. Connect alligator clip to vehicle battery (+).

1. Press switch on remote control.

1. Running noise of pump must be audible.

Note. Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .
2. Check if electrical wiring between flange and fuel pump is connected and has continuity.

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

1. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Scheme 235

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526
2. Connector test set V.A.G 1594
3. Adapter cable V.A.G 1598/39
4. Test box V.A.G 1598/42

Test conditions

1. Battery voltage at least 12.5 V.

1. Fuse on fuse panel S228 (position 28) OK.
2. Ignition switched off.

Check voltage supply for Fuel Pump (FP) (from Fuel Pump (FP) Control Module J538)

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward the right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

Scheme 236

1. Fold protective boot back.
2. For voltage testing, connect hand multimeter V.A.G 1526 B with measuring probes and connector adapters from connector test set V.A.G 1594 C or V.A.G 1594 A between clamp - 1 - and - 4 - , as shown in illustration. The electrical connection remains connected.

Note. Connector sockets are numbered respectively on the rear side of the connector.

1. Start engine.

1. Specified value during start and while running at idle: 4 to 5.7 V.

1. Depress accelerator pedal completely and then release it (brief throttle burst).

1. Specification: The voltage value must first rise slightly, then fall and then rise again to the previously read value.

If reading does not result as described

1. Check voltage supply and activation of Fuel Pump (FP) Control Module J538.

Check voltage supply for Fuel Pump (FP) Control Module J538

1. Disconnect electrical harness connector - arrow - on Fuel Pump (FP) Control Module J538.

Scheme 237

1. Connect multimeter between terminal - 3 - and - 4 - of harness connector for voltage measurement.
2. Switch ignition on.

1. Specification: approx. battery voltage.

If specification is not obtained

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

Check activation of Fuel Pump (FP) Control Module J538

Scheme 238

1. For voltage testing, connect multimeter with measuring probes and connector adapters from connector test set V.A.G 1594 C between clamp - 4 - and - 5 - , as shown in illustration. The electrical connection remains connected.

Note. Connector sockets are numbered respectively on the rear side of the connector.

1. Start engine.

1. Specified value during start and while running at idle: approx. 5.0 V.

1. Depress accelerator pedal completely and then release it (brief throttle burst).

1. Specification: The voltage value must first rise slightly, then fall and then rise again to the previously read value.

If reading does not result as described

1. Switch off ignition.

Scheme 239

1. Connect test box V.A.G 1598/42 to wiring harness with adapter cable V.A.G 1598/39-1 or adapter cable V.A.G 1598/39-2 ; engine control module (ECM) remains connected. Clamp test box Ground (GND) clip to battery negative terminal --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+

Vehicles with 4-cyl. TFSI-engine

Vehicles with 6-cyl. FSI-engine

1. Repair wiring open circuit or short circuit according to wiring diagram.

If no malfunctions are detected

1. Replace Fuel Pump (FP) Control Module J538.

Delivery rate of fuel pump, checking (vehicles with 4-cyl. TFSI-engine)

Special tools, testers and auxiliary items required

Scheme 240

1. Pressure gauge V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/12

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.

1. Fuse on fuse panel S228 (position 28) OK.

1. Fuel Pump (FP) Control Module J538 OK; check --> «Fuel Pump (FP) Control Module J538 , checking (vehicles with FSI engine)»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Ignition switched off.

Test sequence

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Disconnect electrical harness connector - arrow - at locking flange.

1. Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 1 - using an adapter cable from connector test set V.A.G 1594 C.
2. Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit - arrow -.
3. Connect contact - 4 - to vehicle Ground (GND) using a jumper cable from connector test set V.A.G 1594 C.
4. Connect alligator clip to vehicle battery (+).

1. Remove fuel filler cap from fuel filler tube.

Scheme 241

1. Remove engine cover - arrows -.

Scheme 242

1. Disconnect fuel line - arrow - from line connection on engine.

Scheme 243

1. Connect pressure gauge V.A.G 1318 to fuel supply line using adapters V.A.G 1318/11 and V.A.G 1318/12.
2. Connect extension hose - arrow - to pressure gauge and hold it in a measuring container.
3. Open shut-off valve of pressure gauge. The lever points in direction of flow.
4. Generate pressure in fuel system by pressing switch of the remote control and slowly closing shut-off valve of the pressure gauge.

1. Specification: 4 bar positive pressure.

1. From this point on do not move position of shut-off valve.
2. Empty measuring container.
3. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Installation is in reverse order of removal. Note the following

1. Install fuel line.

Torque specifications

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Measuring container, fuel-resistant

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK, checking --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Ignition switched off.

Test sequence

1. Open cover of fuse box at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Remove fuel filler cap from fuel filler tube.

1. Disconnect fuel return hose from line connection on fuel rail pipe.

1. Connect assisting hose onto fuel rail - arrow - and hold it in a measuring container.
2. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Installation is in reverse order of removal. Note the following

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

1. Install fuel return hose.

Delivery rate of fuel pump, checking (vehicles with 6-cyl. FSI-engine)

Special tools, testers and auxiliary items required

1. Pressure gauge V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/12

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.

1. Fuse on fuse panel S228 (position 28) OK.

1. Fuel Pump (FP) Control Module J538 OK; checking --> «Fuel Pump (FP) Control Module J538 , checking (vehicles with FSI engine)»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Ignition switched off.

Test sequence

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Disconnect electrical harness connector - arrow - at locking flange.

1. Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 1 - using an adapter cable from connector test set V.A.G 1594 C.
2. Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit - arrow -.
3. Connect contact - 4 - to vehicle ground (GND) using a jumper cable from connector test set V.A.G 1594 C.
4. Connect alligator clip to vehicle battery (+).

1. Remove fuel filler cap from fuel filler tube.

Scheme 244

1. Remove rear engine cover - arrows -.

Scheme 245

1. Disconnect fuel line - arrow -.

Scheme 246

1. Connect pressure gauge V.A.G 1318 to fuel line using adapter V.A.G 1318/11 and V.A.G 1318/12.
2. Connect extension hose - arrow - to pressure gauge and hold it in a measuring container.
3. Open shut-off valve of pressure gauge. The lever points in direction of flow.
4. Generate pressure in fuel system by pressing switch of remote control and slowly closing shut-off valve of the pressure gauge.

1. Specification: 4 bar positive pressure.

1. From this point on do not move position of shut-off valve.
2. Empty measuring container.
3. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

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

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

Installation is in reverse order of removal.

Torque specifications

Special tools, testers and auxiliary items required

1. Wrench T10202

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Disconnect electrical harness connector - arrow - at locking flange.

Scheme 247

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

1. Pull both lines from locking flange, by pressing release buttons.

Scheme 248

1. Remove locking ring with wrench T10202.
2. Lift fuel delivery unit slightly out of fuel tank opening and remove seal.

Scheme 249

1. If fuel delivery unit is still inserted in fuel tank, slide locking flange slightly to side.
2. Reach through the gap between locking flange and installation opening in fuel tank and pull off suction jet line - 1 - from suction jet pump, by pressing release button.
3. Release suction jet pump - arrows - and remove it.
4. Remove fuel delivery unit.

Note. When removing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G. Be aware that fuel is still in the fuel delivery unit.

Installation is in reverse order of removal. Note the following

Note. Replace seal. When installing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G. Make sure fuel hoses are seated securely.

1. Insert fuel delivery unit into fuel tank.
2. Clip in suction jet pump on fuel delivery unit. To do so, insert hand into gap between locking flange and installation opening of fuel tank.

1. Suction jet pump must engage audibly.

1. Verify that the suction jet pump is securely engaged.
2. Push suction jet pipe - 1 - onto connection of suction jet pump until it engages audibly.
3. Install new locking flange seal dry.
4. Press locking flange down against spring pressure and bring it into installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.

1. Install fuel supply line - 1 - and fuel return line - 2 - according to marking.
2. Connect electrical harness connector.
3. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Fuel pump adaptation after replacing fuel delivery unit, (vehicles with 4-cyl. TFSI engine)

Special tools, testers and auxiliary items required

Scheme 250

1. Vehicle diagnostic, testing, and information system VAS 5051 (VAS 5051 B version shown as example only)

Note. If the fuel pump is replaced, the fuel pump should be adapted to the engine control module on vehicles with 4-cyl. TFSI engine to check the repair.

Work procedure

1. Vehicle Diagnostic, Testing and Information System VAS 5051 connected, On-board diagnostics and vehicle system "01 Engine electronics" selected.
2. No DTCs in DTC memory.
3. Engine running at idle.

Scheme 251

Display on VAS 5051

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

Scheme 252

Display on VAS 5051

1. Select function "103" in button field - 2 - for "display group 103" and press Q to confirm input.

Scheme 253

1. Activate basic setting by pressing Activate button - A -.

Display on VAS 5051

1. Check indication in display field - 4 -.

Scan tool display: "ADP in progress". After the fuel pump adaptation is completed, the display shows "ADP OK".

Note. If "ADP not OK" is displayed: Check DTC Memory.

1. End function "04 - Basic setting" by pressing <-- button.
2. From selection, click on the diagnostic function "06 - End output".
3. Turn ignition off and disconnect diagnostic connection.

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526

1. Connector test set V.A.G 1594 C

Test sequence

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Disconnect electrical harness connector - arrow - at locking flange.

Scheme 254

1. Connect hand multimeter V.A.G 1526 B between terminal - 2 - and - 3 - for resistance measurement.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty" , the fuel delivery unit must be removed --> Fuel delivery unit, removing and installing and the floater of the sensor must be placed in upper or lower end position. With fuel level sensor G removed, the following values are obtained because of the greater deflection of the floater arm

Installation is in reverse order or removal.

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Scheme 255

1. Release retaining tabs - arrows - with a screwdriver and pull Fuel Level Sensor G upward and out.

Scheme 256

1. Disengage electrical connectors - 1 - and - 2 - and disconnect them.

Installing

Installation is in reverse order of removal. Note the following

1. Connect electrical connections - 1 - and - 2 - and check that they are securely engaged.
2. Insert fuel level sensor G in guides on fuel delivery unit and push down until it engages.
3. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , observing notes for connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Note. The fuel system with return line is shown in illustration.

Scheme 257

1 - Bracket

1. For exhaust system

2 - Carrier plate

3 - Fuel supply line

1. From fuel filter
2. To engine
3. Do not kink
4. To disconnect, press release button on connection piece

4 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. Do not kink
3. To disconnect, press release button on connection piece
4. Clipped in on fuel tank

5 - Fuel return line

1. From engine
2. Clipped in on fuel tank

6 - Electrical harness connector

1. For Fuel Tank Lock Switch F314
2. Checking electrical --> «Fuel Tank Lock Switch F314 , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

7 - 2 Nm

8 - Heat shield

1. For fuel delivery connection

9 - 23 Nm

10 - Overflow hose

11 - Rubber gasket

12 - Circlip

13 - Seal

1. Replace if damaged

14 - Cap

15 - Ground (GND) connection

1. For discharging electrostatic charge
2. Installed position/check requirements «Position of Ground (GND) connection»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__position-of-ground-gnd-connection)
3. After installing, check electrical connection of metal ring at fuel filler tube to a bare area of chassis using Ohm meter - Specified value: approx. 0 ohms

16 - Ventilation line

17 - Spring clip

18 - Ventilation line

1. From gravity valve to EVAP canister
2. To remove, press release ring on EVAP canister

19 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. To remove, press release ring on EVAP canister
3. Clipped in on fuel tank

20 - Fuel tank

1. Removing and installing --> «Fuel tank with attachments, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

21 - Securing strap

22 - Spreader clip

23 - 23 Nm

24 - Heat shield

1. For fuel tank

25 - 2 Nm

26 - 23 Nm

Position of Ground (GND) connection

1. Route Ground (GND) connection as shown in .
2. Hook Ground (GND) connection contact - 1 - into opening on fuel tank - 4 -.
3. Make sure Ground (GND) connection connector - 3 - fits securely at metal ring - 2 - of fuel filler tube.

Special tools, testers and auxiliary items required

Scheme 258

1. Wrench T10202

1. Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

1. Pull cone piece - 2 - from shaft end - 1 - of fuel extraction unit VAS 5190.
2. Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,865 mm from end of suction hose.

1. Remove fuel filler cap from fuel filler tube.
2. Screw shaft end - 1 - of fuel siphoning device VAS 5190 on to fuel filler tube of fuel tank.
3. Push suction hose as far into fuel tank until the mark applied earlier - arrow - is positioned on shaft end.

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

1. Drain fuel tank through fuel filler tube as much as possible.
2. Carefully pull out suction hose.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Scheme 259

1. Unbolt cover for right locking flange - arrows -.

Scheme 260

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

Scheme 261

1. Disconnect fuel line - 1 - from locking flange by pressing release button.

Vehicles with 1.8L Turbo engine

1. Separate ventilation line - 2 - to fuel filter at locking flange, by pressing release buttons.

All models

1. Remove locking ring with wrench T10202.

Scheme 262

1. Pull locking flange and sealing ring from opening of fuel tank.
2. Separate electrical connection on inner side of locking flange - arrow -.

Scheme 263

1. Insert suction hose, a dimension of - x - = 800 mm in length, through right opening of fuel tank into left fuel tank chamber.
2. Drain left fuel tank chamber.
3. Install right locking flange again «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , observing notes for connecting battery.

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

Scheme 264

1. Disconnect ventilation line - 1 - by pressing release button.
2. Disconnect ventilation line - 2 -.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for locking flange, left and right - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disconnect electrical connector - 2 -.

Scheme 265

1. Disconnect electrical harness connector - arrow - at left locking flange.

1. Open tank flap and clean area around fuel filler tube.

Note. Do not remove fuel cap.

1. Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.

Scheme 266

1. Remove right rear wheel.
2. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Remove ventilation lines - 2 - and - 3 - at fuel filler tube.
4. Remove - 1 - for fuel filler tube.

1. Remove EVAP canister cover at bottom of spare wheel well - arrows -.

1. Disconnect ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Unclip ventilation lines - A - at top from bracket - arrow -.
3. Remove rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
4. Remove drive shaft --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar) for REAR FINAL DRIVE 0AR .

1. Remove rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 267

1. Remove heat shields - 1 - and - 2 -.

Scheme 268

1. Disconnect parking brake cables at positions indicated by - arrows -.

Fuel system with return line

1. Disconnect fuel supply line - 1 - from fuel filter, by pressing release buttons. Catch escaping fuel.
2. Disconnect fuel return line - 3 - and ventilation line - 2 - at connection point, by pressing release buttons.

Fuel system without return line

Scheme 269

1. Disconnect fuel line - 1 - and right ventilation line - 2 - from fuel tank, by pressing release buttons.

All models

1. Place engine/transmission jack V.A.G 1383 A under fuel tank for support.

Scheme 270

1. Remove bolts - 1 through 10 -.
2. Lower fuel tank with engine/transmission jack VA.G. 1383 A , by guiding it by hand.

Installing

Installation is in reverse order of removal. Note the following

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

1. Make sure the fuel and ventilation lines are properly clipped to the fuel tank.
2. Check if Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
3. Check installation position of Ground (GND) connection

1. The connector - 3 - must be securely attached to metal ring - 2 -.
2. The contact - 1 - must be hooked into fuel tank - 4 -.

1. Position fuel tank with mounting straps and carrier plate to vehicle floor using engine/transmission jack V.A.G 1383 A.
2. Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of the body.

1. Fasten mounting straps and carrier plate - 1 through 10 -.
2. Fasten fuel filler tube.

1. Install rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install drive shaft --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar) for REAR FINAL DRIVE 0AR .
3. Install rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
4. Install right rear wheel housing liner, thereby fastening bolt for fuel filler tube --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Scheme 271

1 - Fuel Level Sensor G

1. Clipped onto baffle housing in fuel tank
2. Resistance values, checking --> «Fuel Level Sensor G , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
3. Removing and installing --> «Fuel Level Sensor G , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

2 - Fuel delivery unit

1. Different versions, allocation
2. Can only be replaced together with flange
3. Fuel pump electrical, checking --> «Fuel pump electrical, checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
4. Checking residual pressure --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF

1. Removing and installing --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

3 - Electrical harness connector

1. For Fuel level sensor G
2. For Transfer Fuel Pump (FP) G6

4 - Locking flange

1. For fuel delivery unit
2. Cannot be replaced separately
3. Installed location --> (Scheme 279)

5 - Seal

1. Replace
2. Install dry

6 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

7 - Fuel line

1. To fuel filter
2. To disconnect, press release button on connection piece
3. Do not kink
4. Clipped in on fuel tank

8 - Distribution piece

1. Different versions, allocation
2. Clipped in on baffle housing with catches
3. To remove, press toward right so that catches disengage and lift upward

9 - Suction jet pipe

1. To suction jet pump in baffle housing

10 - Suction jet pipe

1. From left locking flange

11 - Fuel delivery line

1. From suction jet pump, left side

12 - Baffle housing

1. With suction jet pump

Scheme 272

1 - Baffle housing

1. With suction jet pump

2 - Distribution piece

1. Different versions, allocation
2. Clipped in on baffle housing with catches
3. To remove, press toward right so that catches disengage and lift upward

3 - Suction jet pipe

1. To suction jet pump in baffle housing

4 - Suction jet pipe

1. From left locking flange

5 - Fuel line

1. From engine/from fuel filter
2. To disconnect, press release button on connection piece
3. Do not kink
4. Clipped in on fuel tank

6 - Oil seal

1. Replace
2. Install dry

7 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

8 - Electrical harness connector

1. For Fuel Level Sensor 2 G169

9 - Locking flange

1. Installed location «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

10 - Fuel Level Sensor 2 G169

1. Resistance values, checking --> «Fuel Level Sensor 2 G169 , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-2-g169)
2. Removing and installing --> «Fuel Level Sensor 2 G169 , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-2-g169)

11 - Suction jet pump

1. With lines
2. Different versions, allocation
3. Secured to locking flange
4. Function --> «Suction jet pump, function»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__suction-jet-pump-function)

1. Removing and installing --> «Suction jet pump in left fuel tank chamber, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__suction-jet-pump-in-left-fuel)

12 - Fuel delivery line

1. From suction jet pump, left side

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Portable multimeter V.A.G 1526
3. Connector test set V.A.G 1594

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuse on fuse panel S228 (position 28) OK.

1. Fuel Pump (FP) Relay J17 - arrow - at position 1 in 9-socket relay carrier behind driver side storage compartment is OK.
2. Fuel filter OK
3. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Press switch on remote control.

1. Running noise of pump must be audible.

Note. Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.

Note. Ignore - 2 -.

1. Connect hand multimeter V.A.G 1526 between terminal - 1 - and - 4 - for voltage measurement.
2. Press switch on remote control.

1. Specification: approx. battery voltage.

If specification is not obtained

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

If specified value is obtained, although no running-noise can be heard at pump

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Scheme 273

1. Check if electrical wiring between flange and fuel pump is connected and has continuity.

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

1. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Fuel pump delivery quantity, checking (vehicles with 1.8L Turbo engine)

Special tools, testers and auxiliary items required

1. Adapter V.A.G 1318/17-1 from adapter set V.A.G 1318/17

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK, checking --> 24 MULTIPORT FUEL INJECTION (MFI) .

1. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Remove fuel filler cap from fuel filler tube.
4. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for left locking flange - arrows -.

Scheme 274

1. Pull fuel line - arrow - off from left locking flange, by pressing release button.

1. Connect adapter V.A.G 1318/17-1 to disconnected fuel line and hold it in a measuring container.
2. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Installation is in reverse order of removal. Note the following

1. Install fuel line.

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK, checking --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to the right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Remove fuel filler cap from fuel filler tube.

1. Disconnect fuel return hose from line connection on fuel rail pipe.

1. Connect extension hose onto fuel rail - arrow - and hold it in a measuring container.
2. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Assembly is performed in the reverse order of removal. Note the following

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

1. Install fuel return hose.

Special tools, testers and auxiliary items required

1. Wrench T10202

Scheme 275

1. Fuel pump wrench 3307

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

1. Disconnect fuel line - 1 - from locking flange by pressing release button.

Vehicles with 1.8L Turbo engine

1. Disconnect ventilation line - 2 - to fuel filter at locking flange, by pressing the release buttons.

All models

1. Remove locking ring using wrench T10202.
2. Pull locking flange and sealing ring from opening of fuel tank.

1. Disconnect electrical connection on inner side of locking flange - arrow -.

Scheme 276

Note. To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

1. Guide fuel pump wrench 3307 through the fuel tank opening and place it on the fuel delivery unit.
2. Release fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward left until stop (bayonet connection).

Scheme 277

1. Notch - 1 - aligns with marking - 2 -.

1. Remove fuel delivery unit.

Note. Be aware that fuel is still in the fuel delivery unit.

Installation is in reverse order of removal. Note the following

Note. Replace seal.

1. Insert fuel delivery unit into baffle housing in tank so that the notch - 1 - at fuel delivery unit aligns with marking - 2 - at baffle housing.

1. Fuel delivery unit can be pressed downward significantly and noticeably.

1. Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.

Scheme 278

1. Fasten fuel delivery unit using fuel pump wrench 3307 , thereby turning approx. 15 ° toward right until stop (bayonet connection).

1. Notch - 1 - aligns with marking - 3 -.

1. Connect electrical connection - arrow - on inner side of locking flange.
2. Install new locking flange seal dry.
3. Bring locking flange to installation position.

Scheme 279

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 C

1. Connector test set V.A.G 1594 C

Test sequence

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.

Note. Ignore - 2 -.

Scheme 280

1. Connect hand multimeter V.A.G 1526 B between terminal - 2 - and - 3 - for resistance measurement.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty" , the fuel level sensor G must be removed --> Fuel Level Sensor G , removing and installing and the floater of the sensor must be placed in upper or lower end position. With fuel level sensor G removed, the following values are obtained because of the greater deflection of the floater arm

Special tools, testers and auxiliary items required

1. Wrench T10202

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

1. Disconnect fuel line - 1 - from locking flange by pressing release button.

Vehicles with 1.8L Turbo engine

1. Disconnect ventilation line - 2 - to fuel filter at locking flange, by pressing release buttons.

All models

1. Remove locking ring using wrench T10202.
2. Pull locking flange and sealing ring from opening of fuel tank.

1. Disconnect electrical connection on inner side of locking flange - arrow -.

Scheme 281

1. While pressing retaining tab, pull out fuel level sensor G from guide in baffle housing - arrows -.

Note. To improve clarity, the baffle housing is shown without the fuel tank.

Installation is in reverse order of removal. Note the following

Note. Replace seal.

Scheme 282

1. Place fuel level sensor G into guide in outer part of baffle housing and press it downward - arrow - until it is audibly engaged.

1. Connect electrical connection - arrow - on inner side of locking flange.
2. Install new locking flange seal dry.
3. Bring locking flange to installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Fuel Level Sensor 2 G169 , checking

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 B

1. Connector test set V.A.G 1594 C

Test sequence

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for left locking flange - arrows -.

1. Disconnect electrical harness connector - arrow - at left locking flange.

Scheme 283

1. Connect hand multimeter V.A.G 1526 B between terminal - 2 - and - 3 - for resistance measurement.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty" , the fuel level sensor 2 G169 must be removed --> Fuel Level Sensor 2 G169 , removing and installing and the sensor floater must be placed in upper or lower end position. With Fuel Level Sensor 2 G169 removed, the following values are obtained because of the greater deflection of the floater arm

Fuel Level Sensor 2 G169 , removing and installing

Special tools, testers and auxiliary items required

1. Wrench T10202

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for left locking flange - arrows -.

1. Disconnect electrical harness connector - arrow - at left locking flange.

1. Pull fuel line - arrow - off from left locking flange, by pressing release button.

1. Remove left locking ring using wrench T10202.
2. Carefully pull locking flange with Fuel Level Sensor 2 G169 and seal slightly out of fuel tank opening.

Scheme 284

1. First remove fuel line - 1 - from fuel tank.
2. Pivot locking flange - 2 - with fuel level sensor 2 G169 - 3 - and suction jet pump - 4 - out of fuel tank opening.

Note. When removing, be sure not to bend floater arm of fuel level sensor 2 G169.

1. Unclip suction jet pump from locking flange with Fuel Level Sensor 2 G169.

Scheme 285

1. Press release buttons - arrows - and separate fuel hose at the Y-fitting.
2. Remove locking flange with fuel level sensor 2 G169.

Installation is in reverse order of removal. Note the following

Note. Replace seal. When installing, be sure not to bend floater arm of fuel level sensor 2 G169. Make sure fuel hose is seated securely.

1. Install new locking flange seal dry.
2. Bring locking flange to installation position.

Scheme 286

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Suction jet pump, function

Note. Arrow - points in direction of travel.

Scheme 287

1 - Left suction jet pump

1. The fuel tank in a vehicle with all-wheel drive is divided into a left and right chamber.
2. To move the volume of fuel from the left fuel tank chamber to right baffle housing - 8 - of the fuel delivery unit, a suction jet pump - 1 - is utilized.
3. A second suction jet pump - 7 - is positioned in the right fuel tank chamber and improves fuel supply to the baffle housing of the fuel delivery unit.
4. Function of the suction jet pumps is based on a simple physical principle: A suction jet from the fuel return line - 3 - is compressed by a nozzle in the suction jet pumps - 1 - and - 7 - and is thereby accelerated. This acceleration causes the surrounding fuel to be drawn in and be forced to the baffle housing of the fuel delivery unit. The right suction jet pump - 7 - delivers directly into the baffle housing, the left suction jet pump - 1 - via a separate line - 4 -.

1. The fuel from the return line is distributed to both suction jet pumps via the Y-fitting - 2 -. The distribution piece - 6 - limits the pressure in the lines to the suction jet pumps to approx. 1 bar. Excess fuel is guided into the baffle housing via a direct line.

Suction jet pump in left fuel tank chamber, removing and installing

Special tools, testers and auxiliary items required

1. Wrench T10202

1. Fuel pump wrench 3307

Removing

Note. The following describes removal of suction jet pump for left half of fuel tank. The suction jet pump on the right side of the fuel tank is a component of the baffle housing and cannot be replaced separately.

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

1. Disconnect fuel line - 1 - from right locking flange by pressing release button.

Vehicles with 1.8L Turbo engine

1. Disconnect ventilation line - 2 - to fuel filter at locking flange, by pressing release buttons.

All models

1. Remove locking ring using wrench T10202.

1. Pull locking flange and sealing ring from opening of fuel tank.
2. Disconnect electrical connection on inner side of locking flange - arrow -.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

1. Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
2. Release fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward left until stop (bayonet connection).

1. Notch - 1 - aligns with marking - 2 -.

1. Remove fuel delivery unit.

Note. Be aware that fuel is still in the fuel delivery unit.

1. Unbolt cover for left locking flange - arrows -.

1. Disconnect electrical harness connector - arrow - at left locking flange.

1. Pull fuel line - arrow - off from left locking flange, by pressing release button.

1. Remove left locking ring using wrench T10202.
2. Carefully pull locking flange with Fuel Level Sensor 2 G169 and seal slightly out of fuel tank opening.

1. Remove fuel line - 1 - from fuel tank.
2. Pivot locking flange - 2 - with fuel level sensor 2 G169 - 3 - and suction jet pump - 4 - out of the fuel tank opening.

Note. When removing, be sure not to bend floater arm of fuel level sensor 2 G169.

1. Unclip suction jet pump from locking flange with Fuel Level Sensor 2 G169.

1. Press release buttons - arrows - and separate fuel hose at the Y-fitting.

Scheme 288

1. Reach into fuel tank opening on right side of vehicle and pull suction jet line - 4 - out of baffle housing.
2. Push distribution piece - 1 - toward right and unclip it from the baffle housing.
3. Disconnect fuel return line - 3 - at distribution piece - 1 -.

Note. The fuel line - 2 - remains connected.

1. Reach into fuel tank opening on left side of vehicle and pull suction jet pump with lines out toward the left.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace seals. Make sure fuel hoses are seated securely.

1. Push suction jet pump with lines at left side of vehicle into fuel tank opening.
2. Reach into fuel tank opening on right side of vehicle and pull suction jet pump with lines into installed position.

1. Push fuel return line - 3 - on at distribution piece - 1 - , until hose couplings are engaged.
2. Clip distribution piece to baffle housing.
3. Insert fuel delivery line - 4 - into corresponding hole of baffle housing.

1. Clip suction jet pump - 4 - to locking flange - 2 - of fuel level sensor 2 G169 , and connect fuel line to Y-coupling - 1 -.

Note. When installing, be sure not to bend floater arm of fuel level sensor 2 G169.

1. Install new locking flange seal dry.
2. Bring locking flange of Fuel Level Sensor 2 G169 to installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

1. Insert fuel delivery unit into baffle housing in tank so that the notch - 1 - at fuel delivery unit aligns with marking - 2 - at baffle housing.

1. Fuel delivery unit can be pressed downward significantly and noticeably.

1. Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.

1. Fasten fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward right until stop (bayonet connection).

1. Notch - 1 - aligns with marking - 3 -.

1. Connect electrical connection - arrow - on inner side of locking flange.
2. Install new locking flange seal dry.
3. Bring locking flange to installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

The Fuel Tank Lock Switch F314 consists of a reed contact on fuel filler tube and a fuel tank cap with an embedded magnet. If fuel tank cap is not fully screwed on, the reed contact switches on an indicator in the instrument cluster.

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 C

1. Connector test set V.A.G 1594 C

1. If indicator is lit, check the following points in order

1. Fuel tank cap is completely screwed on.
2. Correct fuel tank cap (Identification: Threads are gray in color).

1. Switch - arrow - at fuel filler tube is fully inserted.
2. Electrical malfunction in switch.
3. Wiring connection to instrument cluster is faulty (check according to schematics).

Fuel Tank Lock Switch F314 , checking electrical

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical connector - 2 -.

Note. Ignore - 1 -.

1. Connect hand multimeter V.A.G 1526 B between terminal - 1 - and - 2 - for resistance measurement.

If specifications are not obtained

1. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Replace Fuel Tank Lock Switch F314 - arrow - , thereby unclipping and clipping in the switch and electrical wiring at fuel filler tube.

Scheme 289

1 - Bracket

1. For exhaust system

2 - Carrier plate

3 - Fuel line

1. From fuel filter
2. To engine
3. Do not kink
4. To disconnect, press release button on connection piece

4 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. Do not kink
3. To disconnect, press release button on connection piece
4. Clipped in on fuel tank

5 - Electrical harness connector

1. For Fuel Tank Lock Switch F314
2. Checking electrical --> «Fuel Tank Lock Switch F314 , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

6 - 2 Nm

7 - Heat shield

1. For fuel delivery connection

8 - 23 Nm

9 - Overflow hose

10 - Rubber gasket

11 - Circlip

12 - Seal

1. Replace if damaged

13 - Cap

14 - Ground (GND) connection

1. For discharging electrostatic charge
2. Installed position/check requirements «Installation position of Ground (GND) connection»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
3. After installing, check electrical connection of metal ring at fuel filler tube to a bare area of chassis using Ohm meter - Specified value: approx. 0ohms

15 - Ventilation line

16 - Ventilation line

1. From gravity valve to EVAP canister
2. To remove, press release ring on EVAP canister

17 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. To remove, press release ring on EVAP canister
3. Clipped in on fuel tank

18 - Fuel tank

1. Removing and installing --> «Fuel tank with attachments, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

19 - Spreader clip

20 - 23 Nm

21 - Securing strap

22 - Heat shield

1. For fuel tank

23 - 2 Nm

24 - 23 Nm

1. Route Ground (GND) connection as shown in illustration.
2. First hook Ground (GND) connection contact - 1 - into securing hole on fuel tank - 5 - and then press in spacer bushing - 2 -.
3. Make sure connector of Ground (GND) connection - 4 - fits securely at metal ring - 3 - of fuel filler tube.

Special tools, testers and auxiliary items required

1. Wrench T10202

1. Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

1. Pull cone piece - 2 - from shaft end - 1 - of fuel extraction unit VAS 5190.
2. Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,865 mm from end of suction hose.
3. Remove fuel filler cap from fuel filler tube.

1. Screw shaft end - 1 - of fuel extraction unit VAS 5190 on to fuel filler tube of fuel tank.
2. Push suction hose as far into fuel tank until mark applied earlier - arrow - is positioned on shaft end.

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

1. Drain fuel tank through fuel filler tube as much as possible.
2. Carefully pull out suction hose.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

1. Disconnect fuel line - 1 - from locking flange by pressing release button.
2. Disconnect ventilation line - 2 - by pressing release buttons.

1. Remove locking ring with wrench T10202.
2. Pull locking flange and sealing ring from opening of fuel tank.

1. Disconnect electrical connection on the inner side of the locking flange - arrow -.

1. Insert suction hose, a dimension of - x - = 800 mm in length, through right opening of fuel tank into left fuel tank chamber.
2. Drain left fuel tank chamber.
3. Install right locking flange again «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , observing notes for connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

Scheme 290

1. Disconnect ventilation line - 1 -. Do this by pressing releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for locking flange, left and right - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disconnect electrical connector - 2 -.

1. Disconnect electrical harness connector - arrow - at left locking flange.
2. Open tank flap and clean area around fuel filler tube.

Note. Do not remove fuel cap.

1. Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward the inside.
2. Remove right rear wheel.
3. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Remove ventilation line - 2 - from fuel filler tube by pressing release buttons.
2. Remove bolt - 1 - for fuel filler tube.

1. Remove EVAP canister cover at bottom of spare wheel well - arrows -.

1. Disconnect ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Unclip ventilation lines - A - at top from bracket - arrow -.
3. Remove rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
4. Remove drive shaft --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar) for REAR FINAL DRIVE 0AR .

1. Remove rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Remove heat shields - 1 - and - 2 -.

1. Disconnect parking brake cables at positions indicated by - arrows -.

1. Disconnect fuel line - 1 - and right ventilation line - 2 - from fuel tank, by pressing release buttons.
2. Place engine/transmission jack V.A.G 1383 A under fuel tank for support.

1. Remove bolts - 1 through 10 -.
2. Lower fuel tank using engine/transmission jack V.A.G 1383 A.

Installing

Installation is in reverse order of removal. Note the following

1. Make sure fuel and ventilation lines are properly clipped to fuel tank.
2. Check if Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
3. Check installation position of Ground (GND) connection

1. The connector - 4 - must be securely attached to metal ring - 3 -.
2. The contact - 1 - must be attached into fuel tank - 5 - and be secured with spacer bushing - 2 -.

1. Position fuel tank with mounting straps and carrier plate to vehicle floor using engine/transmission jack V.A.G 1383 A.
2. Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of the body.

1. Fasten mounting straps and carrier plate - 1 through 10 -.
2. Fasten fuel filler tube.

1. Install rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install drive shaft --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar) for REAR FINAL DRIVE 0AR .
3. Install rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
4. Install right rear wheel housing liner, thereby fastening fuel filler tube screws --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Scheme 291

1 - Fuel Level Sensor G

1. Clipped onto baffle housing in fuel tank
2. Resistance values, checking --> «Fuel Level Sensor G , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
3. Removing and installing --> «Fuel Level Sensor G , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

2 - Fuel delivery unit

1. Different versions, allocation
2. Can only be replaced together with flange
3. Fuel pump electrical, checking --> «Fuel pump electrical, checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
4. Checking residual pressure --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF

1. Removing and installing --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

3 - Electrical harness connector

1. For Fuel level sensor G
2. For Transfer Fuel Pump (FP) G6

4 - Locking flange

1. For fuel delivery unit
2. Cannot be replaced separately
3. Installed location --> see scheme 440

5 - Ventilation line

1. From fuel pressure regulator in fuel filter
2. To disconnect, press release button on connection piece
3. Do not kink
4. Clipped in on fuel tank

6 - Seal

1. Replace
2. Install dry

7 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

8 - Fuel supply line

1. To fuel filter
2. To disconnect, press release button on connection piece
3. Do not kink
4. Clipped in on fuel tank

9 - Distribution piece

1. Different versions, allocation
2. Clipped in on baffle housing with catches
3. To remove, press toward right so that catches disengage and lift upward

10 - Fuel line

1. To suction jet pump in baffle housing

11 - Fuel return line

1. From left locking flange

12 - Fuel delivery line

1. From suction jet pump, right side

13 - Baffle housing

1. With suction jet pump

Part 2 (left chamber)

1 - Baffle housing

1. With suction jet pump

2 - Distribution piece

1. Different versions, allocation
2. Clipped in on baffle housing with catches
3. To remove, press toward right so that catches disengage and lift upward

3 - Fuel line

1. To suction jet pump in baffle housing

4 - Fuel return line

1. From left locking flange

5 - Fuel return line

1. From engine/from fuel filter
2. To disconnect, press release button on connection piece
3. Do not kink
4. Clipped in on fuel tank

6 - Seal

1. Replace
2. Install dry

7 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

8 - Electrical harness connector

1. For Fuel Supply Sensor 2 G169

9 - Locking flange

1. Installed location «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

10 - Fuel supply sensor 2 G169

1. Resistance values, checking --> «Fuel Level Sensor 2 G169 , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
2. Removing and installing --> «Fuel Level Sensor 2 G169 , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

11 - Suction jet pump

1. With lines
2. Different versions, allocation
3. Secured to locking flange
4. Function --> «Suction jet pump, function»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

1. Removing and installing --> «Suction jet pump in left fuel tank chamber, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

12 - Fuel delivery line

1. From suction jet pump, right side

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Portable multimeter V.A.G 1526 B
3. Connector test set V.A.G 1594 C

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuse on fuse panel S228 (position 28) OK.

1. Fuel Pump (FP) Relay J17 - arrow - at position 1 in 9-socket relay carrier behind the driver side storage compartment is OK.
2. Fuel filter OK
3. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to the right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Press switch on remote control.

1. Running noise of pump must be audible.

Note. Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.

Note. Ignore - 2 -.

1. Connect hand multimeter V.A.G 1526 B between terminal - 1 - and - 4 - for voltage measurement.
2. Press switch on remote control.

1. Specification: approx. battery voltage.

If specification is not obtained

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

If specified value is obtained, although no running-noise can be heard at pump

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

1. Check if electrical wiring between flange and fuel pump is connected and has continuity.

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

1. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Fuel Pump (FP) delivery quantity, checking

Special tools, testers and auxiliary items required

1. Adapter V.A.G 1318/17-1 from adapter set V.A.G 1318/17

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK
3. Fuel tank at least 1 / 4 filled.
4. Fuel pressure regulator OK, checking --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Ignition switched off.

Test sequence

1. Open fuse box cover at left side of instrument cluster.
2. Pull out fuse on fuse panel S228 (left row, 5th large fuse from top).

1. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to right socket terminal of S228.
2. Connect alligator clip to vehicle battery (+).
3. Remove fuel filler cap from fuel filler tube.
4. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for left locking flange - arrows -.

1. Pull fuel line - arrow - off from left locking flange, by pressing release button.

1. Connect adapter V.A.G 1318/17-1 to disconnected fuel line and hold it in a measuring container.
2. Press switch on remote control for 15 seconds.

1. Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and pump running is approx. 2 volts less than battery voltage.

Installation is in reverse order of removal. Note the following

1. Install fuel return line.
2. Install rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Special tools, testers and auxiliary items required

1. Wrench T10202

1. Fuel pump wrench 3307

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

1. Disconnect fuel line - 1 - from locking flange by pressing release button.
2. Disconnect ventilation line - 2 - by pressing release buttons.

1. Remove locking ring using wrench T10202.
2. Pull locking flange and sealing ring from opening of fuel tank.

1. Disconnect electrical connection on the inner side of the locking flange - arrow -.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

1. Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
2. Release fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward left until stop (bayonet connection).

1. Notch - 1 - aligns with marking - 2 -.

1. Remove fuel delivery unit.

Note. Be aware that fuel is still in the fuel delivery unit.

Installation is in reverse order of removal. Note the following

Note. Replace seal.

1. Insert fuel delivery unit into baffle housing in tank so that the notch - 1 - at fuel delivery unit aligns with marking - 2 - at baffle housing.

1. Fuel delivery unit can be pressed downward significantly and noticeably.

1. Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
2. Fasten fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward right until stop (bayonet connection).

1. Notch - 1 - aligns with marking - 3 -.

1. Connect electrical connection - arrow - on inner side of locking flange.
2. Install new locking flange seal dry.
3. Bring locking flange to installation position.

1. The tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 C

1. Connector test set V.A.G 1594 C

Test sequence

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.

Note. Ignore - 2 -.

1. Connect hand multimeter V.A.G 1526 between terminal - 2 - and - 3 - for resistance measurement.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty" , the fuel level sensor G must be removed --> Fuel Level Sensor G , removing and installing and the floater of the sensor must be pivoted to the upper or lower end position. With fuel level sensor G removed, the following values are obtained because of the greater deflection of the floater arm

Special tools, testers and auxiliary items required

1. Wrench T10202

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

1. Disconnect fuel line - 1 - from locking flange by pressing release button.
2. Disconnect ventilation line - 2 - by pressing release buttons.

1. Remove locking ring using wrench T10202.
2. Pull locking flange and sealing ring from opening of fuel tank.

1. Disconnect electrical connection on inner side of locking flange - arrow -.

1. While pressing retaining tab, pull out fuel level sensor G from guide in baffle housing - arrows -.

Note. To improve clarity, the baffle housing is shown without the fuel tank.

Installation is in reverse order of removal. Note the following

Note. Replace seal.

1. Place fuel level sensor G into guide in outer part of baffle housing and press it downward - arrow - until it is audibly engaged.

1. Connect electrical connection - arrow - on inner side of locking flange.
2. Install new locking flange seal dry.
3. Bring locking flange to installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 C

1. Connector test set V.A.G 1594 C

Test sequence

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for left locking flange - arrows -.

1. Disconnect electrical harness connector - arrow - at left locking flange.

1. Connect hand multimeter V.A.G 1526 between terminal - 2 - and - 3 - for resistance measurement.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty" , the Fuel Level Sensor 2 G169 must be removed --> Fuel Level Sensor 2 G169 , removing and installing and the floater of the sensor must be placed in upper or lower end position. With Fuel Level Sensor 2 G169 removed, the following values are obtained because of the greater deflection of the floater arm

Special tools, testers and auxiliary items required

1. Wrench T10202

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Unbolt cover for left locking flange - arrows -.

1. Disconnect electrical harness connector - arrow - at left locking flange.

1. Pull fuel line - arrow - off from left locking flange, by pressing release button.

1. Remove left locking ring using wrench T10202.
2. Carefully pull locking flange with Fuel Level Sensor 2 G169 and seal slightly out of fuel tank opening.

1. Remove fuel line - 1 - from fuel tank.
2. Pivot locking flange - 2 - with fuel level sensor 2 G169 - 3 - and suction jet pump - 4 - out of fuel tank opening.

Note. When removing, be sure not to bend floater arm of fuel level sensor 2 G169.

1. Unclip suction jet pump from locking flange with Fuel Level Sensor 2 G169.

1. Press release buttons - arrows - and separate fuel hose at the Y-fitting.
2. Remove locking flange with fuel level sensor 2 G169.

Installation is in reverse order of removal. Note the following

Note. Replace seal. When installing, be sure not to bend floater arm of fuel level sensor 2 G169. Make sure fuel hose is seated securely.

1. Install new locking flange seal dry.
2. Bring locking flange to installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Note. Arrow - points in direction of travel.

1 - Left suction jet pump

1. The fuel tank in a vehicle with all-wheel drive is divided into a left and right chamber.
2. To move the volume of fuel from the left fuel tank chamber to the right baffle housing - 8 - of the fuel delivery unit, a suction jet pump - 1 - is utilized.
3. A second suction jet pump - 7 - is positioned in the right fuel tank chamber and improves the fuel supply to the baffle housing of the fuel delivery unit.
4. Function of the suction jet pumps is based on a simple physical principle: A suction jet from the fuel return line - 3 - is compressed by a nozzle in the suction jet pumps - 1 - and - 7 - and is thereby accelerated. This acceleration causes the surrounding fuel to be drawn in and be forced to the baffle housing of the fuel delivery unit. The right suction jet pump - 7 - delivers directly into the baffle housing, the left suction jet pump - 1 - via a separate line - 4 -.

1. The fuel from the return line is distributed to both suction jet pumps via the Y-fitting - 2 -. The distribution piece - 6 - limits the pressure in the lines to the suction jet pumps to approx. 1 bar. Excess fuel is guided into the baffle housing via a direct line.

Special tools, testers and auxiliary items required

1. Wrench T10202

1. Fuel pump wrench 3307

Removing

Note. The following describes removal of suction jet pump for left half of fuel tank. The suction jet pump for the right side of the fuel tank is a component of the baffle housing and cannot be replaced separately.

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Open fuel filler flap briefly and then close again.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical harness connector - 1 - at right locking flange.
2. Disengage electrical harness connector - 2 - and lay it aside.

1. Disconnect fuel line - 1 - from right locking flange by pressing release button.
2. Disconnect ventilation line - 2 - by pressing release buttons.

1. Remove locking ring using wrench T10202.

1. Pull locking flange and sealing ring from opening of fuel tank.
2. Disconnect electrical connection on inner side of locking flange - arrow -.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

1. Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
2. Release fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward left until stop (bayonet connection).

1. Notch - 1 - aligns with marking - 2 -.

1. Remove fuel delivery unit.

Note. Be aware that fuel is still in the fuel delivery unit.

1. Unbolt cover for left locking flange - arrows -.

1. Disconnect electrical harness connector - arrow - at left locking flange.

1. Pull fuel line - arrow - off from left locking flange, by pressing release button.

1. Remove left locking ring using wrench T10202.

1. Carefully pull locking flange with Fuel Level Sensor 2 G169 and seal slightly out of fuel tank opening.
2. Remove fuel line - 1 - from fuel tank.
3. Pivot locking flange - 2 - with fuel level sensor 2 G169 - 3 - and suction jet pump - 4 - out of fuel tank opening.

Note. When removing, be sure not to bend floater arm of fuel level sensor 2 G169.

1. Unclip suction jet pump from locking flange with Fuel Level Sensor 2 G169.

1. Press release buttons - arrows - and separate fuel hose at the Y-fitting.

1. Reach into fuel tank opening on right side of vehicle and pull suction jet line - 4 - out of baffle housing.
2. Push distribution piece - 1 - toward right and unclip it from baffle housing.
3. Disconnect fuel return line - 3 - at distribution piece - 1 -.

Note. The fuel line - 2 - remains connected.

1. Reach into fuel tank opening on left side of vehicle and pull suction jet pump with lines out toward left.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace seals. Make sure fuel hoses are seated securely.

1. Push suction jet pump with lines at left side of vehicle into fuel tank opening.
2. Reach into fuel tank opening on right side of vehicle and pull suction jet pump with lines into installed position.

1. Push fuel return line - 3 - on at distribution piece - 1 - , until hose couplings are engaged.
2. Clip distribution piece to baffle housing.
3. Insert fuel delivery line - 4 - into corresponding hole of baffle housing.

1. Clip suction jet pump - 4 - to locking flange - 2 - of fuel level sensor 2 G169 , and connect fuel line to Y-coupling - 1 -.

Note. When installing, be sure not to bend floater arm of fuel level sensor 2 G169.

1. Install new locking flange seal dry.
2. Bring locking flange of Fuel Level Sensor 2 G169 to installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

1. Insert fuel delivery unit into baffle housing in tank so that the notch - 1 - at the fuel delivery unit aligns with marking - 2 - at baffle housing.

1. Fuel delivery unit can be pressed downward significantly and noticeably.

1. Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
2. Fasten fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward right until stop (bayonet connection).

1. Notch - 1 - aligns with marking - 3 -.

1. Connect electrical connection - arrow - on inner side of locking flange.
2. Install new locking flange seal dry.
3. Bring locking flange to installation position.

1. Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note. Arrow - points in direction of travel.

1. Tighten locking ring.
2. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

The Fuel Tank Lock Switch F314 consists of a reed contact on fuel filler tube and a fuel tank cap with an embedded magnet. If fuel tank cap is not fully screwed on, the reed contact switches on an indicator in instrument cluster.

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 C

1. Connector test set V.A.G 1594 C

1. If indicator is lit, check the following points in order

1. Fuel tank cap is completely screwed on.
2. Correct fuel tank cap (Identification: Threads are gray in color).

1. Switch - arrow - at fuel filler tube is fully inserted.
2. Electrical malfunction in switch.
3. Wiring connection to instrument cluster is faulty (check according to schematics).

Fuel Tank Lock Switch F314 , checking electrical

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

1. Disconnect electrical connector - 2 -.

Note. Ignore - 1 -.

1. Connect hand multimeter V.A.G 1526 between terminal - 1 - and - 2 - for resistance measurement.

If specifications are not obtained

1. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Replace Fuel Tank Lock Switch F314 - arrow - , thereby unclipping and clipping in the switch and electrical wiring at fuel filler tube.

Scheme 292

1 - Bracket

1. For exhaust system

2 - Carrier plate

3 - Fuel line

1. From fuel filter
2. To engine
3. Do not kink
4. To disconnect, press release button on connection piece

4 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. Do not kink
3. To disconnect, press release button on connection piece
4. Clipped in on fuel tank

5 - 2 Nm

6 - Tire protection shield

1. For fuel delivery connection

7 - 23 Nm

8 - Overflow hose

9 - Rubber gasket

10 - Circlip

11 - Seal

1. Replace if damaged

12 - Cap

13 - Ground (GND) connection

1. For discharging electrostatic charge
2. Installed position/check requirements «Installation position of Ground (GND) connection»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
3. After installing, check electrical connection of metal ring at fuel filler tube to a bare area of chassis using Ohm meter - Specified value: approx. 0ohms

14 - Ventilation line

15 - Ventilation line

1. From gravity valve to EVAP canister
2. To remove, press release ring on EVAP canister

16 - Ventilation line

1. From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
2. To remove, press release ring on EVAP canister
3. Clipped in on fuel tank

17 - Fuel tank

1. Removing and installing --> «Fuel tank with attachments, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

18 - Spreader clip

19 - 23 Nm

20 - Securing strap

21 - Heat shield

1. For fuel tank

22 - 2 Nm

23 - 23 Nm

1. Route Ground (GND) connection as shown in .
2. First hook Ground (GND) connection contact - 1 - into securing hole on fuel tank - 5 - and then press in spacer bushing - 2 -.
3. Make sure connector of Ground (GND) connection - 4 - fits securely at metal ring - 3 - of fuel filler tube.

Special tools, testers and auxiliary items required

1. Wrench T10202

1. Fuel siphoning unit VAS 5190

Work procedure

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

All except Audi RS4

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Audi RS4

1. Raise luggage compartment floor covering and secure.

Scheme 293

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

All

1. Pull cone piece - 2 - from shaft end - 1 - of fuel extraction unit VAS 5190.
2. Using insulating tape, apply a mark - arrow - on hose at length - a - = 1,865 mm from end of suction hose.
3. Remove fuel filler cap from fuel filler tube.

1. Screw shaft end - 1 - of fuel extraction unit VAS 5190 on to fuel filler tube of fuel tank.
2. Push suction hose as far into fuel tank until mark applied earlier - arrow - is positioned on shaft end.

Note. If using a siphoning device without shaft end, proceed basically in the same manner.

1. In this case, apply a mark - arrow - using insulating tape on hose at length - a - = 1,800 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
2. If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

1. Drain fuel tank through fuel filler tube as much as possible.
2. Carefully pull out suction hose.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.
2. Disconnect electrical harness connector - arrow - at right locking flange.

Audi RS4

Scheme 294

1. Free up electrical connector - arrow - for Fuel Pump (FP) Control Module J538 and disconnect.

All

Scheme 295

1. Disconnect electrical harness connector - arrow - at right locking flange.

Scheme 296

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

1. Pull both lines from locking flange, by pressing release buttons.

1. Remove locking ring using wrench T10202.
2. Pull locking flange and sealing ring from opening of fuel tank.

1. Insert suction hose, a dimension of - x - = 800 mm in length, through right opening of fuel tank into left fuel tank chamber.
2. Drain left fuel tank chamber.
3. Install right locking flange again «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) , observing notes for connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

All except Audi RS4

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Audi RS4

1. Remove carpeting in luggage compartment.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

All

1. Open fuel filler flap briefly and then close again.

Sedan

1. Remove carpeting in luggage compartment.
2. Fold forward right rear seat backrest, if necessary.

Wagon

1. Remove left 1/3 backrest --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
2. Remove left side luggage compartment trim and dirt tray --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

All models

1. Unbolt cover for locking flange in luggage compartment - arrows -.

1. Separate ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line off - arrow B -.
2. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for locking flange, left and right - arrows -.

Audi RS4

1. Remove electrical wires with connector - arrow - from locking flange opening and lay them aside.

All

1. Disconnect electrical harness connector - arrow - at right locking flange.

Scheme 297

1. Disconnect electrical harness connector - arrow - at left locking flange.
2. Open tank flap and clean area around fuel filler tube.

Note. Do not remove fuel cap.

1. Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.
2. Remove right rear wheel.
3. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Pull ventilation line - 2 - off from fuel filler tube by pressing release buttons.
2. Remove bolt - 1 - for fuel filler tube.

1. Remove EVAP canister cover at bottom of spare wheel well - arrows -.

1. Separate ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
2. Unclip ventilation lines - A - at top from bracket - arrow -.

Audi RS4

Scheme 298

1. Remove bolt - 1 -.
2. Remove EVAP canister cover at bottom of spare wheel well - arrows -.
3. Disconnect purge lines - 1 - and ventilation lines - 2 - by pressing the release button.

Scheme 299

1. Unclip lines from bracket - arrow -.

All

1. Remove rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
2. Remove drive shaft --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar) for REAR FINAL DRIVE 0AR .

1. Remove rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Remove heat shields - 1 - and - 2 -.

1. Disconnect parking brake cables at positions indicated by - arrows -.

Scheme 300

1. Separate fuel line - 2 - and ventilation line - 1 - at right front from fuel tank, by pressing release buttons.
2. Place engine/transmission jack V.A.G 1383 A under fuel tank for support.

1. Remove bolts - 1 through 10 -.
2. Lower fuel tank using engine/transmission jack V.A.G 1383 A by guiding it by hand.

Installing

Installation is in reverse order of removal. Note the following

1. Make sure fuel and ventilation lines are properly clipped to fuel tank.
2. Check if the Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
3. Check installation position of Ground (GND) connection

1. Connector - 4 - must be securely attached to metal ring - 3 -.
2. Contact - 1 - must be attached into fuel tank - 5 - and be secured with spacer bushing - 2 -.

1. Position fuel tank with mounting straps and carrier plate to vehicle floor using engine/transmission jack V.A.G 1383 A.
2. Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of body.

1. Fasten mounting straps and carrier plate - 1 through 10 -.
2. Fasten fuel filler tube.

1. Install rear axle --> «42 - REAR SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install drive shaft --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar) for REAR FINAL DRIVE 0AR .
3. Install rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .
4. Install right rear wheel housing liner, thereby fastening the bolt for fuel filler tube --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Scheme 301

1 - Fuel Level Sensor G

1. Resistance values, checking --> «Fuel Level Sensor G , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
2. Removing and installing --> «Fuel Level Sensor G , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

2 - Fuel delivery unit

1. Different versions, allocation
2. Fuel pump electrical, checking --> «Fuel pump electrical, checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
3. Checking residual pressure --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF
4. Removing and installing --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

3 - Seal

1. Replace
2. Install dry

4 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

5 - Fuel supply line

1. To fuel filter
2. Do not kink
3. Mark before removing
4. To remove from locking flange, press release button on connecting piece

1. Note direction of arrow (fuel supply or return) on locking flange when installing
2. Clipped in on fuel tank

6 - Fuel return line

1. From fuel filter
2. Do not kink
3. Mark before removing
4. To remove from locking flange, press release button on connecting piece

1. Note direction of arrow (fuel supply or return) on locking flange when installing
2. Clipped in on fuel tank

7 - Electrical harness connector

1. For Fuel level sensor G
2. For Transfer Fuel Pump (FP) G6

8 - Suction jet pipe

1. From fuel pump to suction jet pump
2. To disconnect, press release button on connection piece

9 - Electrical harness connector

1. For Fuel Level Sensor 2 G169

10 - Locking ring

1. Use wrench T10202 to remove and install
2. Tighten to 145 Nm

11 - Seal

1. Replace
2. Install dry

12 - Suction jet pump

1. Suction jet pump, checking --> «Suction jet pump»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
2. Removing and installing --> «Suction jet pump, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__suction-jet-pump-removing-and-installing)

13 - Fuel Level Sensor 2 G169

1. Resistance values, checking --> «Fuel Level Sensor 2 G169 , checking»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)
2. Removing and installing --> «Fuel Level Sensor 2 G169 , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system)

14 - Fuel delivery line

1. From suction jet pump to fuel delivery unit
2. Clipped into fuel delivery unit

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
2. Portable multimeter V.A.G 1526 B
3. Connector test set V.A.G 1594 C

Test conditions

1. Battery voltage at least 12.5 V.

1. Fuse on fuse panel S228 (position 28) OK.

1. Vehicles with MPI engine: Fuel Pump (FP) Relay J17 - arrow - at position 1 in 9-socket relay carrier behind driver side storage compartment is OK.

Scheme 302

1. Vehicles with FSI engine: Fuel Pump (FP) Control Module J538 OK; checking --> «Fuel Pump (FP) Control Module J538 , checking (vehicles with 4-cyl. TFSI engine)»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-pump-fp-control-module-j538) .
2. Fuel filter OK
3. Ignition switched off.

Test sequence

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

Audi RS4

1. Remove electrical wires with connector - arrow - from locking flange opening and lay them aside.

All

1. Disconnect electrical harness connector - arrow - at right locking flange.

1. Connect remote control V.A.G 1348/3 A with connection V.A.G 1348/3-3 to contact - 1 - using an adapter cable from connector test set V.A.G 1594 C.
2. Using insulating tape, tape over the second contact of connection V.A.G 1348/3-3 to prevent a short circuit - arrow -.
3. Connect contact - 4 - to vehicle Ground (GND) using a jumper cable from the connector test set V.A.G 1594 C.
4. Connect alligator clip to vehicle battery (+).

1. Press switch on remote control.

1. Running noise of pump must be audible.

Note. Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

1. Remove fuel delivery unit --> «Fuel delivery unit, removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

1. Check if electrical wiring between flange and fuel pump is connected and has continuity.

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

1. Install fuel delivery unit «Installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system) .

Fuel Pump (FP) Control Module J538 , checking (vehicles with 4-cyl. TFSI engine)

Special tools, testers and auxiliary items required

1. Portable multimeter V.A.G 1526 B
2. Connector test set V.A.G 1594 C
3. Adapter cable V.A.G 1598/39
4. Test box V.A.G 1598/42

Test conditions

1. Battery voltage at least 12.5 V.

1. Fuse on fuse panel S228 (position 28) OK.
2. Ignition switched off.

Check voltage supply for Fuel Pump (FP) (from Fuel Pump (FP) Control Module J538)

1. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.
2. Fold protective boot back.

1. For voltage testing, connect the hand multimeter V.A.G 1526 B with measuring probes and connector adapters from the connector test set V.A.G 1594 C or V.A.G 1594 A between clamp - 1 - and - 4 - , as shown in illustration. The electrical connection remains connected.

Note. Connector sockets are numbered respectively on the rear side of the connector.

1. Start engine.

1. Specified value during start and while running at idle: 4 to 5.7 V.

1. Depress accelerator pedal completely and then release it (brief throttle burst).

1. Specification: The voltage value must first rise slightly, then fall and then rise again to the previously read value.

If the reading does not result as described

1. Check voltage supply and activation of Fuel Pump (FP) Control Module J538.

Check voltage supply for Fuel Pump (FP) Control Module J538

1. Remove Fuel Pump (FP) Control Module J538 --> «Fuel Pump (FP) Control Module J538 , removing and installing»(/audi/a4/b7-2004-2009/remont/fuel-system/#fuel-supply-system__fuel-pump-fp-control-module-j538) .

1. Disconnect electrical harness connector - arrow - on Fuel Pump (FP) Control Module J538.

1. Connect multimeter between terminal - 3 - and - 4 - of harness connector for voltage measurement.
2. Switch ignition on.

1. Specification: approx. battery voltage.

If specification is not obtained

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

Check activation of Fuel Pump (FP) Control Module J538

1. Remove protective cap.

1. For voltage testing, connect the multimeter with measuring probes and connector adapters from the connector test set V.A.G 1594 C between clamp - 4 - and - 5 - , as shown in illustration. The electrical connection remains connected.

Note. Connector sockets are numbered respectively on the rear side of the connector.

1. Start engine.

1. Specified value during start and while running at idle: approx. 5.0 V.

1. Depress accelerator pedal completely and then release it (brief throttle burst).

1. Specification: The voltage value must first rise slightly, then fall and then rise again to the previously read value.

If the reading does not result as described

1. Switch off ignition.

1. Connect test box V.A.G 1598/42 to wiring harness with adapter cable V.A.G 1598/39-1 or adapter cable V.A.G 1598/39-2 ; engine control module (ECM) remains connected. Clamp test box Ground (GND) clip to battery negative terminal --> 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-278897-S07807171762008020700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS «24 MULTIPORT FUEL INJECTION (MFI)»(ref-278895-S12545223132008020700000) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF .

1. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+

1. Repair wiring open circuit or short circuit according to wiring diagram.

If no malfunctions are detected

1. Replace Fuel Pump (FP) Control Module J538.

Fuel Pump (FP) Control Module J538 , checking (vehicles with 6-cyl. and 8-cyl. FSI engine)

Fuel Pump (FP) Control Module J538 is checked in "Guided Fault Finding" with Vehicle Diagnostic, Testing and Information System VAS 5051.

Fuel Pump (FP) Control Module J538 , removing and installing

Removing

Observe safety precautions --> Safety precautions when working on fuel supply system .

Observe rules for cleanliness --> Rules for cleanliness .

All except Audi RS4

1. Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Audi RS4

1. Raise luggage compartment floor covering and secure.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

All

1. Open tank flap and clean area around fuel filler tube.

Note. Do not remove fuel cap.

1. Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.
2. Remove right rear wheel.
3. Remove right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Unfasten bolts - 1 - for fuel filler tube.

Note. Ignore - 2 -.

Scheme 303

1. Remove right rear cover - 1 - on bottom of vehicle floor.

1. Loosen screws - 1, 2, 3, 4, 5, 9, 10 - a maximum of 8 turns.
2. Remove bolts - 6, 7, 8 -.
3. Remove rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

1. Unbolt cover for right locking flange - arrows -.

Audi RS4

1. Free up electrical connector - arrow - for Fuel Pump (FP) Control Module J538 and disconnect.

All

1. Disconnect electrical harness connector - arrow - at locking flange.

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

1. Pull both lines from locking flange, by pressing release buttons.

Scheme 304

1. Remove bolts - arrows -.
2. Remove Fuel Pump (FP) Control Module J538 between fuel tank and vehicle floor.

Installing

Installation is in reverse order of removal. Note the following

1. Fasten mounting straps and carrier plate - 1 through 10 -.

1. Fasten fuel filler tube with Ground (GND) connection using bolt - 1 -.

Note. Ignore - 2 -.

1. Install right rear wheel housing liner --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Install rear seat bench --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .
3. Connect battery. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET .

Torque specifications

Fuel pump delivery quantity, checking (vehicles with 4-cyl. TFSI-engine)

Special tools, testers and auxiliary items required

1. Pressure gauge V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/12

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
2. Fuel-resistant measuring container

Test conditions

1. Battery voltage at least 12.5 V.
2. Fuel filter OK