Fuel Supply, Generic Scan Tool (2.8l v6 Aha, Atq) Audi A6 C5

Fuel supply system components, removing and installing

Note. Hose connections are secured with screw -type clamps, spring-type clamps or tensioning clamps. Always replace tensioning clamps with spring-type clamps or screw-type clamps. Fuel hoses at engine must only be secured with spring - type clamps. The use of clamping collars or screw clamps is not permitted. see scheme 1: Identifying VAS5024A Spring Clip Installation Tool VAS5024A spring clip installation tool is recommended for installing spring-type clips.

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

Observe rules for cleanliness. See RULES OF CLEANLINESS .

Component overview of fuel tank with attachments

1. Front Wheel Drive (FWD) vehicles. See «FUEL TANK WITH ATTACHMENTS, COMPONENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) .
2. All Wheel Drive (AWD) vehicles. See «ALL WHEEL DRIVE (AWD) VEHICLES»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__all-wheel-drive-awd-vehicles) .

Component overview of Fuel Pump (FP) and sender for fuel gauge

1. Front Wheel Drive (FWD) vehicles. See «FUEL PUMP (FP) AND SENDER FOR FUEL GAUGE, COMPONENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) .
2. All Wheel Drive (AWD) vehicles. See «ALL WHEEL DRIVE (AWD) VEHICLES»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) .

Removing and installing parts of the EVAP canister system. See PARTS OF EVAP CANISTER SYSTEM, REMOVING AND INSTALLING .

Electronic engine power control (E -Gas), checking. See ELECTRONIC ENGINE POWER CONTROL (E-GAS) .

Safety precautions when working on fuel supply

Always observe the following when removing and installing the sender for fuel gauge or the Fuel Pump (FP) from full or partially filled fuel tanks.

1. Before starting work, switch on exhaust extraction system and place an extraction hose close to the sensor opening in 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.
2. Prevent gasoline from contacting skin! Wear fuel - resistant gloves!

Rules of cleanliness

When working on the fuel supply or fuel injection systems, the following "5 rules of cleanliness" should be carefully observed

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

Front Wheel Drive (FWD) vehicles

All Wheel Drive (AWD) vehicles ALL WHEEL DRIVE (AWD) VEHICLES .

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

Fuel Tank With Attachments (FWD) - Component Overview. Scheme 556

Part I

Note. The following list refers to items in (Scheme 557).

1. Fuel return line From engine Mark before removing Note direction of arrow on connector flange Clipped in on fuel tank, at front right
2. Fuel supply line To fuel filter Mark before removing Note direction of arrow on connector flange Clipped in on fuel tank, at front right
3. Bolt M8 x 35 with permanent washer Tighten to 23 Nm Serves to secure fuel filler neck and Ground (GND) connection, item no. 9
4. Overflow hose
5. Rubber top
6. Tensioning ring
7. Cap
8. Seal Replace if damaged
9. Ground (GND) connection Installed position / check requirements. See «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__installation-position-of-ground-gnd-connection) . Ensure secure seating of connector and secure wire with securing bolt for fuel filler neck, item no. 3. After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using ohmmeter. Specified value: approx. 0
10. Vent line to EVAP canister
11. Vent line
12. Vent line
13. Fuel tank
14. Tension strap Note varying lengths Installation position: Locating point (hole) faces direction of travel
15. Bolt M8 x 28 with permanent washer Tighten to 23 Nm

Fuel Tank With Attachments (FWD) - Component Overview (Part I). Scheme 557

Part II

Note. The following list refers to items in (Scheme 558).

1. Fuel filler tube with reservoir
2. O-ring Always replace
3. Gravity valve not available separately as replacement part To remove, unclip valve upward from filler tube Checking valve for throughput Valve vertical: open, Valve tilted 45° : closed
4. Pressure retention valve Clipped onto fuel filler tube Vents fuel tank for pressure equalization
5. Ground (GND) connection Installed position/check requirements. See «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__installation-position-of-ground-gnd-connection) . ensure secure fit of connector at metal ring of fuel filler tube Bolt wire contact with securing bolt for fuel filler tube, item no. 3. after installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using ohmmeter - Specified value: approx. 0 ohm.
6. Seal Installation position: Sealing lip faces fuel filler tube
7. O-Rings Different sizes Always replace
8. Bleeder valve
9. Hose coupling To remove, press release button
10. to EVAP canister

Fuel Tank Filler Neck Components (FWD) - Component Overview (Part II). Scheme 558

Installation Position Of Ground (GND) Connection

Note. Check the installation position with fuel tank removed.

Identifying Installation Position Of Ground (GND) Connection (FWD). Scheme 559

1. Route Ground (GND) connection (arrow) as shown in figure.
2. Ensure connector of Ground (GND) connection fits securely at metal ring of fuel filler tube.
3. Check whether contact is locked at edge of securing hole.
4. Bolt wire contact -1- with securing bolt -2- for fuel filler tube.

Bolting Wire Contact With Securing Bolt For Fuel Filler Tube (FWD). Scheme 560

All Wheel Drive (AWD) vehicles

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

Note. The following list refers to items in (Scheme 561).

1. Bolt M8 x 28 with permanent washer Tighten to 23 Nm
2. Mounting clip For heat shield Check for secure fitting
3. Heat shield for fuel tank
4. Carrier plate
5. Tension strap Note installed position
6. Fuel return line From engine Mark before removing Note direction of arrow on connector flange Clipped in on fuel tank, at front right
7. Vent line Front end to Evaporative Emission (EVAP) Canister Purge Regulator Valve - N80- clipped in at top of fuel tank Remains on fuel tank when fuel tank is removed
8. Fuel supply line from fuel filter To fuel rail Mark before removing Note direction of arrow on connector flange Clipped in on fuel tank, at front right
9. 2 Nm
10. Heat shield for fuel filler tube
11. Vent line Rear end to EVAP canister clipped in at top of fuel tank Remains on fuel tank when fuel tank is removed
12. Bolt M8 x 28 with permanent washer Tighten to 23 Nm Serves to secure fuel filler neck and Ground (GND) connection, item no. 18
13. Overflow hose
14. Cap
15. Seal Replace if damaged
16. Tensioning ring
17. Rubber top
18. Ground (GND) connection Installed position / check requirements. See «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) . Ensure secure seating of connector and secure wire with front securing bolt for fuel filler neck, item no. 12. After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter Specified value: approx. 0
19. Fuel filler tube with reservoir can be replaced separately
20. Vent line to EVAP canister
21. Fuel tank

Identifying All Wheel Drive (AWD) Vehicle Fuel Tank Components. Scheme 561

Note. Check the installation position with fuel tank/fuel filler tube removed.

Identifying Installation Position Of Ground (GND) Connection (AWD). Scheme 562

1. Route Ground (GND) connection (arrow) as shown in figure.
2. Ensure connector of Ground (GND) connection fits securely at metal ring of fuel filler tube.
3. Check whether contact is locked at edge of securing hole. see scheme 9: Identifying Bolt Wire Contact With Securing Bolt For Fuel Filler Tube (AWD)
4. Bolt wire contact -1- with securing bolt -2- for fuel filler tube.

All Wheel Drive (AWD) vehicles, see ALL WHEEL DRIVE (AWD) VEHICLES .

Note. The following list refers to items in (Scheme 563).

1. Sender for fuel gauge -G
2. Fuel screen not individually replaceable Clean if soiled
3. Fuel pump Can be replaced only complete with connector flange Removing and installing, see «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) Checking Fuel Pump (FP), «FUEL PUMP, CHECKING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq)
4. Connector flange not individually replaceable Installation position: Note arrow marking
5. Fuel return line From engine Mark before removing Note direction of arrow on connector flange
6. Fuel supply line To fuel filter Mark before removing Note direction of arrow on connector flange
7. Seal Always replace to install, place into opening of fuel tank when dry
8. Union nut -80 Nm Use ring nut spanner 3217 to remove and install
9. Harness connector for Fuel Pump (FP) and Sender for fuel gauge -G- Releasing, see «RELEASING HARNESS CONNECTOR»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__releasing-harness-connector) .
10. O-Rings Always replace Check installation position
11. Return line Disconnect to remove fuel tank from connector flange
12. Baffle housing lower part With suction jet pump Fuel tank not depicted in illustration

Fuel Pump And Sender For Fuel Gauge Component Overview (Front Wheel Drive Vehicle). Scheme 563

Note. The following list refers to items in (Scheme 564).

1. Fuel line From union piece to suction jet pump in baffle housing lower part Component of baffle housing not individually replaceable Connect to union piece -item 3
2. Baffle housing lower part With suction jet pump
3. Union piece Clipped in on baffle housing with catches To remove, press toward left so that catches disengage and lift upward Insert fuel line into baffle housing when installing Different versions, allocation See Parts Catalog.
4. Wiring From sender 1 for fuel gauge to sender 2 for fuel gauge Secured with 2 cable ties -item 6 - at suction jet pump lines
5. Sender for fuel gauge -GClipped in at baffle housing in fuel tank
6. Cable ties Fuel resistant
7. Locking ring Use ring nut spanner 3087 to remove and install Tighten to 120 Nm
8. Seal Always replace to install, place into opening of fuel tank when dry
9. Fuel Level Sensor 2 -G169- Drain fuel tank before removing
10. Suction jet pump With lines Secured to fuel level sensor 2 Different versions, allocation See Parts Catalog.

Fuel Pump And Sender For Fuel Gauge Component Overview (All Wheel Drive Vehicles, Part I). Scheme 564

Note. The following list refers to items in (Scheme 565).

1. Union piece Clipped in on baffle housing with 3 catches To remove, press toward left so that catches disengage and lift upward Insert fuel line into baffle housing when installing To remove the Fuel Pump (FP), union piece must be unclipped so that fuel return line (from connector flange) can be disconnected Different versions, allocation See Parts Catalog.
2. Baffle housing lower part With suction jet pump
3. Wiring To Fuel Level Sensor 2 -G169- Connect on connector flange
4. Wiring To Sender for fuel gauge -GConnect on connector flange
5. Harness connector for Fuel Pump (FP) and all senders for fuel gauge Releasing, see «RELEASING HARNESS CONNECTOR»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__releasing-harness-connector) .
6. Return line Clipped in on front at fuel tank Mark before removing
7. Supply line To fuel filter Clipped in on front at fuel tank Mark before removing
8. Locking ring Use ring nut spanner 3087 to remove and install Tighten to 120 Nm
9. Seal Always replace to install, place into opening of fuel tank when dry
10. Connector flange For Fuel Pump (FP) not individually replaceable Installation position: Note arrow marking
11. Fuel pump Different versions, allocation See Parts Catalog. Can be replaced only complete with connector flange Removing and installing, see «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) Checking Fuel Pump (FP), see «FUEL PUMP, CHECKING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq)
12. O-Rings Always replace Check installation position
13. Return line To remove the Fuel Pump (FP), unclip union piece and disconnect fuel return line at union piece -item 1 -, press release button to do so
14. Fuel screen not individually replaceable Clean if soiled

Fuel Pump And Sender For Fuel Gauge Component Overview (All Wheel Drive Vehicles, Part II). Scheme 565

Releasing Harness Connector

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

Releasing Harness Connector. Scheme 566

Special tools and equipment

1. VAG1348/3A remote control with VAG1348/3 -2 adapter cable
2. VAG1526 or VAG1526 A hand-held multimeter
3. VAG1594A connector test kit

1. 3087 wrench for tank sensor

1. 3217 ring nut spanner

Scheme 567

1. Battery voltage at least 12 V
2. Fuse in fuse holder -S228- OK (position 28) (Scheme 567): Identifying Fuse Holder
3. Fuel Pump (FP) relay (position 4) in central electric behind driver's side storage compartment OK. (Scheme 568): Identifying Fuel Pump Relay (Position 4) In Central Electric
4. Fuel filter OK
5. Ignition switched off.

Scheme 568

1. Open cover of fuse box at left side of instrument cluster.
2. Remove Fuse in fuse holder -S228- at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect V.A.G 1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from Fuse in fuse holder -S228- (arrow). (Scheme 569): Connecting V.A.G 1348/3A Remote Control Connection To Fuse 28 Holder
4. Connect alligator clip to vehicle battery B+.
5. Press switch of remote control. Operating noise of the pump must be audible in vicinity of fuel tank. NOTE: Fuel Pump (FP) runs quietly. Surrounding noise should be avoided during test of the Fuel Pump (FP).

If no flowing noise can be heard

Scheme 569

1. Remove rear seat bench. See «REAR SEATS»(/audi/a6/c5-1997-2001/remont/seats/#seats-frames).
2. Unscrew cover at right beneath rear seat bench
3. Carefully disengage and disconnect electrical 4 -pin harness connector (arrow). see scheme 17: Disconnecting Electrical 4-Pin Harness Connector (AWD)

1. Unscrew cover for connector flange below the luggage compartment carpet.
2. Carefully disengage and disconnect electrical 4 -pin harness connector (arrow).

Disconnecting Electrical 4-Pin Harness Connector (FWD). Scheme 570

1. Connect multimeter between terminal 1 and 4 of harness connector for voltage measurement. (Scheme 571): Identifying Fuel Pump 4-Pin Harness Connector Terminals
2. Press switch of remote control. Specified value: approx. battery voltage

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

Scheme 571

Scheme 572

1. Mark fuel supply line -1- and fuel return line -2- and disconnect from connector flange (right side of vehicle). (Scheme 572): Identifying Fuel Supply Line And Fuel Return Line (AWD) WARNING: Connector flange may only be opened when fuel tank is maximum 1/4 full. Otherwise, a large amount of fuel will spill out. Empty fuel tank if necessary. see scheme 21: Removing Locking Ring Using 3087 Wrench (AWD)
2. Use 3087 wrench to remove locking ring.

Identifying Fuel Supply Line And Fuel Return Line (FWD). Scheme 573

1. Mark fuel supply line -2- and fuel return line -1- and disconnect from connector flange. see scheme 23: Removing Union Nut Using Ring Nut Spanner 3217 (FWD)
2. Use ring nut spanner 3217 to remove union nut.

Continuation for all vehicles

1. Pull connector flange and sealing ring from opening of fuel tank.
2. Check whether electrical wires between flange and Fuel Pump (FP) are connected, and test for continuity if necessary.

Testing For Continuity Between Flange And Fuel Pump. Scheme 574

If no malfunctions are found in wires

1. Fuel Pump (FP) faulty, replace fuel pump. See «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) .
2. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

1. VAG1348/3A remote control with VAG1348/3 -2 adapter cable
2. Measuring container

Test requirements

1. Battery voltage at least 12 V
2. Fuel filter OK
3. Ignition switched off.

Scheme 575

Scheme 576

1. Open cover of fuse box at left side of instrument cluster.
2. Remove Fuse in fuse holder -S228- at fuse carrier (position 28) (left row, 5th large fuse from top).
3. Connect V.A.G 1348/3A remote control connection using adapter cables from VAG1348/3-2 at right terminal of socket from Fuse in fuse holder -S228- (arrow). (Scheme 575): Connecting V.A.G 1348/3A Remote Control At Fuse 28 Holder
4. Connect alligator clip to vehicle battery B+.
5. Remove fuel filler cap from fuel filler tube.
6. Remove engine cover (arrows). (Scheme 576): Removing Engine Cover WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
7. Disconnect fuel return hose from line connection on fuel rail pipe. see scheme 27: Connecting Assisting Hose On Distributor Pipe And Hold In Measuring Container
8. Connect assisting hose -arrow- on distributor pipe and hold in a measuring container.
9. Operate remote control for 15 seconds (keep button pressed). (Scheme 578): Minimum Fuel Delivery Rate Versus Fuel Pump Voltage Graph
10. Compare fuel quantity pumped with specified value. *) Minimum delivery rate cm3/15 s **) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage).
11. Install fuel return line with a new hose clamp.

All Wheel Drive (AWD) vehicles, see ALL WHEEL DRIVE (AWD) VEHICLES .

Observe safety precautions, see SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY .

Observe rules for cleanliness. See RULES OF CLEANLINESS .

Identifying 3217 Ring Nut Spanner. Scheme 577

Scheme 578

1. 3217 ring nut spanner (Scheme 579): Identifying Fuel Pump Wrench 3307
2. Fuel Pump Wrench 3307

Scheme 579

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Scheme 584

1. Note and if necessary obtain radio code (for vehicles equipped with coded anti -theft radio).
2. Remove cover above the battery (arrows). (Scheme 580): Removing Cover Above Battery NOTE: For vehicles without separate battery cover: Remove plenum cover.
3. Disconnect battery Ground (GND) strap (arrow) with the ignition switched off. (Scheme 581): Disconnecting Battery Ground (GND) Strap With Ignition Switched Off WARNING: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 1/3. Empty fuel tank if necessary.
4. Unscrew cover for connector flange below the luggage compartment carpet.
5. Carefully disengage and disconnect electrical 4 -pin harness connector (arrow). (Scheme 582): Disconnecting Electrical 4-Pin Harness Connector (FWD) WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. (Scheme 583): Marking Fuel Supply Line And Fuel Return Line And Disconnect From Connector Flange (FWD)
6. Mark fuel supply line -2- and fuel return line -1- and disconnect from connector flange.
7. Use ring nut spanner 3217 to remove union nut. (Scheme 584): Removing Union Nut Using Ring Nut Spanner 3217 (FWD)
8. Pull connector flange and sealing ring from opening of fuel tank.
9. Disconnect harness connector -1- for fuel gauge on inside of connector flange. (Scheme 585): Disconnecting Harness Connector For Fuel Gauge On Inside Of Connector Flange (FWD) NOTE: Harness connector -2- to Fuel Pump (FP) can remain connected.
10. Disconnect fuel return line -3- inside on connector flange, press release button on hose coupling to do so (arrows).
11. Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing. (Scheme 586): Inserting Fuel Pump Wrench 3307 Through Fuel Tank Opening (FWD)
12. Rotate inner part of baffle housing with pump toward left approx. 15° to stop. Notch -1- aligns with marking -2- (bayonet connection)
13. Remove Fuel Pump (FP) with inner part of baffle housing. NOTE: When replacing Fuel Pump (FP) unit, empty old Fuel Pump (FP) unit before disposing.

Installing

Installation is the reverse of removal, noting the following

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

See Parts Catalog.

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

Scheme 591

1. Insert inner part of baffle housing into outer part of baffle housing in fuel tank so the notch -1- on inner part of baffle housing aligns with marking -2- on outer part of baffle housing. (Scheme 588): Inserting Inner Part Of Baffle Housing Into Outer Part Of Baffle Housing In Fuel Tank (FWD) Inner part of baffle housing can be pressed downward significantly and noticeably. NOTE: Baffle housing is shown without fuel tank for the sake of illustration.
2. Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing. (Scheme 589): Inserting Fuel Pump Wrench 3307 Through Fuel Tank Opening (FWD)
3. Rotate inner part of baffle housing with pump toward right approx. 15° to stop. Notch -1- aligns with marking -3- (bayonet connection) (Scheme 590): Aligning Notch With Marking (Bayonet Connection, FWD)
4. Connect fuel return line -2- on inside to connector flange. (Scheme 591): Connecting Fuel Return Line On Inside To Connector Flange (FWD) NOTE: Always use new O -rings for the fuel return line. Coat O-rings for fuel return line with fuel or with lubricant.
5. Insert wire -1- to sender for fuel gauge on connector flange.
6. Insert new, dry seal for connection flange into opening of fuel container.
7. Insert connector flange in fuel tank, note installation position: Marking on connector flange -1- must align with marking on fuel tank -2-. see scheme 43: Aligning Marking On Connector Flange With Marking On Fuel Tank (FWD) NOTE: Black arrow in illustration points in direction of travel. Disregard marking "TDI" on fuel tank.
8. Tighten union nut for connector flange to 80 Nm. (Scheme 593): Tightening Union Nut For Connector Flange (FWD)
9. Connect electrical 4 -pin harness connector.
10. Install fuel supply line -2- and fuel return line -1- according to the marking. (Scheme 594): Installing Fuel Supply Line And Fuel Return Line (FWD)
11. After connecting battery, enter anti-theft code for radio. See Radio operating manual.
12. Fully close power windows to stop.
13. Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
14. Set clock to correct time.
15. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq).
16. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq).

Tightening torques

TIGHTENING TORQUE: FUEL PUMP (FWD)

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

Observe rules for cleanliness. See RULES OF CLEANLINESS .

Identifying 3087 Wrench For Tank Sensor. Scheme 592

Scheme 593

1. 3087 wrench for tank sensor (Scheme 595): Identifying Fuel Pump Wrench 3307
2. Fuel Pump Wrench 3307

Scheme 594

Scheme 595

Scheme 596

Scheme 597

Scheme 598

Scheme 599

Scheme 600

Scheme 601

1. Note and if necessary obtain radio code (for vehicles equipped with coded anti -theft radio).
2. Remove cover above the battery (arrows). (Scheme 596): Removing Cover Above Battery NOTE: For vehicles without separate battery cover: Remove plenum cover.
3. Disconnect battery Ground (GND) strap (arrow) with the ignition switched off. (Scheme 597): Disconnecting Battery Ground Strap With Ignition Switched Off
4. Open fuel tank cap briefly and then close again.
5. To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 1/4. Empty fuel tank if necessary.
6. Remove rear seat bench. See «REAR SEATS»(/audi/a6/c5-1997-2001/remont/seats/#seats-frames).
7. Unscrew cover for connector flange at left beneath rear seat bench (Scheme 598): Disconnecting Electrical 4-Pin Harness Connector (AWD)
8. Carefully disengage and disconnect electrical 4-pin harness connector (arrow). WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
9. Mark fuel supply line -1- and fuel return line -2- and disconnect from connector flange (right side of vehicle). (Scheme 599): Disconnecting Fuel Supply Line And Fuel Return Line From Connector Flange (AWD) WARNING: Connector flange may only be opened when fuel tank is maximum 1/4 full. Otherwise, a large amount of fuel will spill out.
10. Use 3087 wrench to remove locking ring. (Scheme 600): Removing Locking Ring Using 3087 Wrench (AWD)
11. Pull connector flange and sealing ring from opening of fuel tank.
12. Disconnect both harness connectors -1- and -2- to fuel gauge on inside of connector flange. (Scheme 601): Disconnecting Both Harness Connectors And To Fuel Gauge On Inside Of Connector Flange (AWD)
13. Unclip union piece -1- at lower part of baffle housing, to do so, carefully press union piece toward left side of vehicle and lift upward (arrow). (Scheme 602): Disconnecting Fuel Return Line From Union Piece (AWD)
14. Disconnect fuel return line -2- from union piece, release hose coupling for return line to do this. NOTE: Baffle housing is shown without fuel tank for the sake of illustration.
15. Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing. (Scheme 603): Inserting Fuel Pump Wrench 3307 Through Fuel Tank Opening (AWD)
16. Rotate inner part of baffle housing with pump toward left approx. 15° to stop. (Scheme 604): Aligning Notch With Marking (Bayonet Connection, AWD) Notch -1- aligns with marking -2- (bayonet connection)
17. Remove Fuel Pump (FP) with inner part of baffle housing. NOTE: When replacing Fuel Pump (FP) unit, empty old Fuel Pump (FP) unit before disposing.

Installation is the reverse of removal, noting the following

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

See Parts Catalog.

Scheme 602

Scheme 603

Scheme 604

Scheme 605

Scheme 606

Scheme 607

Scheme 608

Scheme 609

Scheme 610

1. Insert inner part of baffle housing into outer part of baffle housing in fuel tank so the notch -1- on inner part of baffle housing aligns with marking -2- on outer part of baffle housing. Inner part of baffle housing can be pressed downward significantly and noticeably. (Scheme 605): Aligning Notch On Inner Part Of Baffle Housing With Marking -2- On Outer Part Of Baffle Housing (AWD)
2. Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing. (Scheme 606): Inserting Fuel Pump Wrench 3307 Through Fuel Tank Opening (AWD)
3. Rotate inner part of baffle housing with pump toward right approx. 15° to stop. Notch -1- aligns with marking -3- (bayonet connection) (Scheme 607): Aligning Notch With Marking (Bayonet Connection, AWD)
4. Insert rigid line -3- and hose line -5- into the corresponding holes of baffle housing -6-. (Scheme 608): Inserting Rigid Line And Hose Line Into Corresponding Holes Of Baffle Housing (AWD)
5. Press on return line -1- on union piece -4- until hose coupling engages. NOTE: Always use new O -rings -7- for the fuel return line. Coat O-rings for fuel return line with fuel or with lubricant.
6. Clip in rigid line -3- on union piece -4-, while doing this the union piece engages itself into baffle housing -6-.
7. Connect harness connectors -1- and -2- for fuel gauge on inside of connector flange. (Scheme 609): Connecting Harness Connectors For Fuel Gauge On Inside Of Connector Flange (AWD)
8. Insert new, dry seal for connection flange into opening of fuel container.
9. When connecting the connector flange, ensure clearance of electrical wires -2- to Fuel Pump (FP) and of return hose -1-. (Scheme 610): Ensuring Clearance Of Electrical Wires To Fuel Pump And Of Return Hose (AWD)
10. When installing, turn connector flange in direction of arrow as shown in illustration. see scheme 63: Turning Connector Flange In Direction Of Arrow When Installing (AWD)
11. Insert connector flange in fuel tank, note installation position: see scheme 64: Aligning Marking On Connector Flange With Marking On Fuel Tank (AWD) Marking on connector flange -1- must align with marking on fuel tank -2-. NOTE: Arrow points in direction of travel.
12. Tighten locking ring (120 Nm). see scheme 65: Tightening Locking Ring (AWD)
13. Install supply and return hose according to marking.
14. Install cover for connector flange so that the protrusion lies over the harness connector.
15. After connecting battery, enter anti -theft code for radio. See Radio operating manual.
16. Fully close power windows to stop.
17. Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
18. Set clock to correct time.
19. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq).
20. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq).

TIGHTENING TORQUES: FUEL PUMP (AWD)

Function of leak diagnostic

The EVAP canister system (incl. fuel tank) is equipped with a leak diagnostic that detects leaks (improper seal) in the system.

The diagnostic is based on pressure characteristics and is intended to detect leaks with diameters greater than 1 mm.

During the diagnostic, the Leak detection pump (LDP) -V144- generates a positive pressure of approx. 30 mbar in the EVAP canister system. The pump is switched off once the pressure is reached. If pressure falls below a specified value, the pump is switched on again. On Board Diagnostic monitors the switch condition and stores a DTC in DTC memory if the intervals are too short.

Note. Hose connections are secured with screw -type clamps, spring-type clamps or tensioning clamps. Always replace tensioning clamps with spring-type clamps or screw-type clamps. Fuel hoses at engine must only be secured with spring-type clamps. The use of clamping collars or screw clamps is not permitted. (Scheme 614): Identifying VAS5024A Spring Clip Installation Tool VAS5024A spring clip installation tool is recommended for installing spring-type clips. Components marked with * are tested via On Board Diagnostic (OBD). See ON BOARD DIAGNOSTIC.

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

Observe rules for cleanliness. See RULES OF CLEANLINESS .

Parts of EVAP canister system, servicing: See PARTS OF EVAP CANISTER SYSTEM, REMOVING AND INSTALLING .

Overview of EVAP canister system: See EVAP CANISTER SYSTEM, OVERVIEW .

EVAP canister system, checking for proper seal: See EVAP CANISTER SYSTEM, CHECKING FOR PROPER SEAL .

Parts of EVAP canister system, removing and installing

Note. The following list refers to items in (Scheme 611).

1. Cap nut - 10 Nm
2. Cover For EVAP canister
3. Stud bolt - 15 Nm
4. Sealing piece
5. Vent line to Evaporative Emission (EVAP) Canister Purge Regulator Valve - N80
6. Vent line From gravity valve at fuel tank
7. Vacuum line Diagnostic pump/throttle valve control module
8. Cable ties for securing vacuum line to Leak Detection Pump (LDP) bracket
9. Leak detection pump (LDP) -V144-* Component location: Under wheel housing liner in rear left wheelhousing Checking, see «LEAK DETECTION PUMP (LDP), CHECKING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq)
10. Connector Black 3-pin
11. Connection hose Leak Detection Pump (LDP)/EVAP canister Pressure side to remove, press release button at connection on Leak Detection Pump (LDP)
12. 10 Nm
13. Air filter housing For diagnostic pump
14. Sealing piece
15. Cable ties for securing connection hose to wheel housing
16. EVAP canister Component location: Bottom of spare tire well, at front

Identifying Parts Of EVAP Canister System. Scheme 611

EVAP canister system, overview

Note. The following list refers to items in (Scheme 612).

1. Throttle Valve Control Module -J338-*
2. Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-* Component location: In engine compartment
3. Vent line From EVAP canister to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- Installation position: Right side, beneath vehicle floor Front Wheel Drive (FWD) vehicles: secured to vehicle floor in fuel tank area All Wheel Drive (AWD) vehicles: secured to fuel tank in fuel tank area
4. Vent line To gravity valve on fuel tank
5. EVAP canister Component location: Bottom of spare tire well
6. Connection hose Leak Detection Pump (LDP)/EVAP canister Pressure side
7. Air filter housing For diagnostic pump
8. Leak detection pump (LDP) -V144-* Component location: Under wheel housing liner in rear left wheelhousing Checking, see «LEAK DETECTION PUMP (LDP), CHECKING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq)
9. Vacuum line Leak Detection Pump (LDP)/throttle valve control module
10. T-piece Component location, see «INSTALLATION POSITION OF T-PIECE»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__installation-position-of-t-piece)

EVAP Canister System - Overview And Vacuum Diagram. Scheme 612

Installation Position Of T-Piece

T-piece (arrow) is located between engine and bulkhead.

1. to EVAP canister
2. to Leak detection pump (LDP) -V144

Identifying Installation Position Of T-Piece. Scheme 613

Function test

1. Select the measuring value "Test-ID 01: Tank leak test" and check whether the specified value is being reached. See «DIAGNOSTIC MODE 8: TANK LEAK TEST»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
2. Check specified value of tank leak test at idle. Specified value: Test OK NOTE: The function test can take a few minutes. If the accelerator pedal is depressed during the test, the test will be aborted. To repeat the tank leak test, switch ignition off and start engine again and let run at idle.
3. End diagnosis and switch ignition off.

If specified value is not obtained

Checking Proper Seal

If a small or large leak was recognized during the test of the EVAP canister system, proceed as follows.

1. Remove wheelhousing liner, rear left.
2. Disconnect hose from diagnostic pump for fuel system at EVAP canister and seal it. See «PARTS OF EVAP CANISTER SYSTEM, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__parts-of-evap-canister-system-removing) .
3. Repeat function test.

If malfunction persists

1. Check the connection lines and hoses between diagnostic pump for fuel system and EVAP canister for proper seal. See «PARTS OF EVAP CANISTER SYSTEM, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__parts-of-evap-canister-system-removing) .
2. Repeat function test.

If malfunction persists

1. Check whether the fuel filler cap is completely closed or whether the seal leaks, replace if necessary.
2. Check whether the union nut of the Fuel Pump (FP) unit is tightened or whether the sealing ring is leaking; replace if necessary. See «FUEL PUMP, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) .
3. Repeat function test.

If malfunction persists

1. Remove EVAP canister and check for cracks and leaks, replace if necessary. See «PARTS OF EVAP CANISTER SYSTEM, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__parts-of-evap-canister-system-removing) .
2. Check connecting lines and hoses between EVAP canister and fuel flap unit or Evaporative Emission (EVAP) Canister Purge Regulator Valve. See «EVAP CANISTER SYSTEM, OVERVIEW»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__evap-canister-system-overview) .
3. Check hoses and hose clamps for secure seating.
4. Repeat function test.

If malfunction is no longer present

1. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
2. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

Evaporative Emission (EVAP) canister purge regulator valve, checking

Solenoid valve is closed when no voltage is present.

Recommended special tools and equipment

1. VAG1526 multimeter or VAG1715 multimeter
2. VAG1594 connector test kit
3. Wiring diagram

Scheme 614

1. The respective fuses of Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- must be OK: (Scheme 615): Identifying Fuse Holder
2. Ignition switched off.

1. Disconnect 2-pin connector -1- from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (arrow) -2-. (Scheme 616): Disconnecting 2-Pin Connector From Evaporative Emission Canister Purge Regulator Valve
2. Measure resistance between terminals of solenoid valve. Specified value: 22.0 to 30.0 ohms (Scheme 617): Measuring Resistance Between Terminals Of EVAP Canister Purge Regulator Solenoid Valve

If specified value is not obtained

1. Replace Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-. See «EVAP CANISTER SYSTEM, OVERVIEW»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__evap-canister-system-overview) , item 2.
2. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

If specified value is obtained

1. Connect test box to control module wiring harness. See «TEST BOX, CONNECTING FOR WIRING TEST»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

1. Check wire between test box socket 15+2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 ohm (Scheme 618): Identifying EVAP Canister Purge Regulator Valve Harness Connector Terminals (Engine Code AHA)

Scheme 615

1. Check wire between test box socket 64+2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5ohm see scheme 74: Identifying EVAP Canister Purge Regulator Valve Harness Connector Terminals (Engine Code ATQ)

1. Also check the wire for short circuit to B+ and Ground (GND). Specified value: INFINITY ohm
2. Check wire between 2 -pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5

If no malfunctions are found in wires

1. Replace Motronic Engine Control Module (ECM) -J220-. See «ENGINE CONTROL MODULE (ECM), REPLACING»(/audi/a6/c5-1997-2001/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-28l-v6-aha-atq__engine-control-module-ecm-replacing) .

1. VAG1526 multimeter or VAG1715 multimeter
2. VAG1594 connector test kit
3. Wiring diagram

Scheme 616

1. The respective fuses of Leak detection pump (LDP) -V144- must be OK: see scheme 75: Identifying Fuse Holder
2. Ignition switched off.

Scheme 617

Scheme 618

1. Remove wheelhousing liner, rear left. See «WHEELHOUSING LINER, REAR»(/audi/a6/c5-1997-2001/remont/mirrors/#exterior-equipment__wheelhousing-liner-rear).
2. Disconnect 3-pin connector of Leak detection pump (LDP) -V144- (arrow). (Scheme 621): Disconnecting 3-Pin Connector Of Leak Detection Pump (LDP) -V144
3. Measure resistance between terminals 1 + 3 of diagnostic pump. see scheme 77: Identifying Leak Detection Pump Connector Terminals Specified value: 640 to 720 ohms
4. Measure resistance between terminals 2 + 3 of diagnostic pump. Specified value: 17.5 to 19.5 ohms

If specified values are not obtained

1. Replace Leak detection pump (LDP) -V144-.
2. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

If specified values are obtained

1. Connect test box to control module wiring harness. See «TEST BOX, CONNECTING FOR WIRING TEST»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

Vehicles with engine code AHA

1. Check wires between test box and 3 -pin connector for open circuits according to wiring diagram. Terminal 1+ socket 37 Terminal 2+ socket 16 Wire resistance: max: 1.5ohm

Identifying Leak Detection Pump Harness Connector Terminals. Scheme 619

Vehicles with engine code ATQ

1. Check wires between test box and 3 -pin connector for open circuits according to wiring diagram. Terminal 1+ socket 80 Terminal 2+ socket 25 Wire resistance: max: 1.5

Identifying Leak Detection Pump Harness Connector Terminals. Scheme 620

1. Also check wires for short circuits to each other, to vehicle Ground (GND) and to B+. Specified value: INFINITY ohm
2. Check wire between 3 -pin connector terminal 3 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 ohm

1. Replace Motronic Engine Control Module (ECM) -J220-. See «ENGINE CONTROL MODULE (ECM), REPLACING»(/audi/a6/c5-1997-2001/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-28l-v6-aha-atq__engine-control-module-ecm-replacing) .

Function of E-Gas system

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

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

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

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

The throttle valve is operated by the throttle drive according to the instructions of the Engine Control Module (ECM).

With the engine at standstill and the ignition switched on, the Engine Control Module (ECM) activates the throttle drive precisely according to the specifications of the Throttle Position (TP) Sensor. This means, if the accelerator pedal is depressed half way, the throttle drive opens the throttle valve to the same degree; i.e. throttle valve is then opened approx. half way.

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

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

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

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

Note. Components marked with * are tested via On Board Diagnostic (OBD). See DIAGNOSTIC MODE 3: CHECK DTC MEMORY .

Parts of electronic engine power regulation (E-gas), servicing

Note. The following list refers to items in see scheme 80.

Scheme 621

1. Socket head bolt -9 Nm
2. 6-pin harness connector
3. Accelerator pedal module with Throttle Position (TP) Sensor -G79-* and Sender -2- for accelerator pedal position -G185-* Not adjustable. Throttle Position (TP) sensor communicates the driver's intentions to the Engine Control Module (ECM) Checking, see «THROTTLE POSITION (TP) SENSOR, CHECKING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq) see scheme 80: Identifying Parts Of Electronic Engine Power Regulation (E-Gas)

Significance of EPC warning lamp

"EPC" is an abbreviation and stands for Electronic Power Control and means "electronic engine load control" (E - gas).

Installation Location Of EPC Warning Lamp. Scheme 622

Installation location of EPC warning lamp

If malfunctions are recognized in the E-gas system during operation of the engine, the Engine Control Module (ECM) switches on the EPC warning lamp. (These malfunctions are listed in the DTC table). An entry is made in DTC memory at the same time.

1. VAG1526 multimeter or VAG1715 multimeter
2. VAG1594 connector test kit
3. Wiring diagram

1. The respective fuses of Electronic Power Control (EPC) Warning Lamp -K132- must be OK: see scheme 82: Identifying Fuse Holder

Test sequence

1. Switch on ignition: Warning lamp must light up.

If warning lamp does not light up when ignition is switched on

1. Switch ignition off.
2. Check wire from Engine Control Module (ECM) to MIL as follows
3. Connect test box to control module wiring harness. See «TEST BOX, CONNECTING FOR WIRING TEST»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
4. Bridge sockets 1 + 48 of test box with the respective adapter cables.
5. Switch on ignition: Warning lamp must light up.

If warning lamp does not light up

1. Switch ignition off.
2. Remove instrument cluster: See «INSTRUMENTS - UP TO 2000»(/audi/a6/c5-1997-2001/remont/gauges-instrument-panels/#instruments-up-to-2000) or «INSTRUMENTS - 2001 AND UP»(ref-196300) .
3. Check wiring connection from Engine Control Module (ECM) to Electronic Power Control (EPC) Warning Lamp - K132- according to wiring diagram.
4. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
5. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

If no malfunctions are detected in wire from Engine Control Module (ECM) to warning lamp

1. Replace Motronic Engine Control Module (ECM) -J220-. See «ENGINE CONTROL MODULE (ECM), REPLACING»(/audi/a6/c5-1997-2001/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-28l-v6-aha-atq__engine-control-module-ecm-replacing) .

If warning lamp lights up when ignition is switched on

1. Start engine and let run at idle: Warning lamp must go out after a few seconds.

If the warning lamp does not go out

1. Switch ignition off.
2. Remove instrument cluster: See «INSTRUMENTS - UP TO 2000»(/audi/a6/c5-1997-2001/remont/gauges-instrument-panels/#instruments-up-to-2000) or «INSTRUMENTS - 2001 AND UP»(ref-196300) .
3. Connect test box to control module wiring harness. See «TEST BOX, CONNECTING FOR WIRING TEST»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
4. Check wire connection between test box socket 48 and instrument cluster for short circuit to Ground (GND) according to wiring diagram
5. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
6. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
7. Replace Motronic Engine Control Module (ECM) -J220-. See «ENGINE CONTROL MODULE (ECM), REPLACING»(/audi/a6/c5-1997-2001/remont/fuel-system/#multiport-fuel-injection-mfi-generic-scan-tool-28l-v6-aha-atq__engine-control-module-ecm-replacing) .

1. VAG1526 multimeter or VAG1715 multimeter
2. VAG1594 connector test kit
3. Wiring diagram

1. The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: see scheme 83: Identifying Fuse Holder

Function

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

Note. When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold -plated terminals.

1. Remove footwell cover (driver's side).
2. Disconnect 6-pin connector from Throttle Position (TP) Sensor.
3. Switch ignition on.

Identifying Accelerator Pedal Module Harness Connector Terminals. Scheme 623

1. Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 +3 Specified value: at least 4.5 V
2. Switch ignition off.

If specified values are not obtained

1. Connect test box to control module wiring harness. See «TEST BOX, CONNECTING FOR WIRING TEST»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq). see scheme 85: Identifying Accelerator Pedal Module Harness Connector Terminals
2. Check wires between test box and 6 -pin connector for open circuit according to wiring diagram. Terminal 1+socket 72 Terminal 2+socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5ohm
3. Also check wires for short circuits to each other, to vehicle Ground (GND) and to B+. Specified value: INFINITY ohm

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

1. Replace accelerator pedal position sensor. See «PARTS OF ELECTRONIC ENGINE POWER REGULATION (E-GAS), SERVICING»(/audi/a6/c5-1997-2001/remont/fuel-system/#fuel-supply-generic-scan-tool-28l-v6-aha-atq__parts-of-electronic-engine-power-regulation) , item 3.
2. Erase DTC memory of Engine Control Module (ECM). See «DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .
3. Generate readiness code. See «READINESS CODE, GENERATING»(/audi/a6/c5-1997-2001/remont/testing-diagnostics/#on-board-diagnostic-obd-generic-scan-tool-28l-v6-aha-atq) .

See also:
• REAR SEATS
• DIAGNOSTIC MODE 4: RESET/ERASE DIAGNOSTIC DATA
• ENGINE CONTROL MODULE (ECM), REPLACING
• WHEELHOUSING LINER, REAR
• INSTRUMENTS - UP TO 2000
• SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY
• RULES OF CLEANLINESS
• FUEL TANK WITH ATTACHMENTS, COMPONENT OVERVIEW
• ALL WHEEL DRIVE (AWD) VEHICLES
• PARTS OF EVAP CANISTER SYSTEM, REMOVING AND INSTALLING
• INSTALLATION POSITION OF GROUND (GND) CONNECTION
• RELEASING HARNESS CONNECTOR
• EVAP CANISTER SYSTEM, OVERVIEW
• INSTALLATION POSITION OF T-PIECE
• PARTS OF ELECTRONIC ENGINE POWER REGULATION (E-GAS), SERVICING