Fuel Supply System - 4.2l v8 (akb, Aux, Ays) Audi A8 D3

General repair instructions

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

Observe rules for cleanliness, see RULES FOR CLEANLINESS .

Checking fuel pump relay and activation

See FUEL PUMP (FP) RELAY -J17- AND RELAY ACTIVATION, CHECKING .

Safety precautions when working on the fuel supply system

Rules for cleanliness

1. Thoroughly clean all connections and the surrounding areas before disconnecting.
2. Place removed parts clean surface and cover them over. Use plastic sheeting or paper. Do not use fluffy rags.
3. Carefully cover or seal opened components if the repair cannot be carried out immediately.
4. Only install clean components (parts): Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored without packing (e.g. in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Avoid moving vehicle if possible.

Note. Secure all hose connections with the correct hose clips (same as original equipment) See Parts catalog Hose clip pliers VAG1921 are recommended when installing spring-type clips. Always replace sealing rings and gaskets when assembling. The arrows on the hose and pipe connections should be aligned with each other. Removing, installing and checking fuel expansion tank, see FUEL FILLER NECK WITH EXPANSION TANK, COMPONENT OVERVIEW

The following list pertains to (Scheme 1).

1. 23 Nm
2. Cross brace Installation position, see «POSITION OF CROSS BRACE»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__position-of-cross-brace) Flexible packing pieces must be installed between cross brace and securing straps.
3. Fuel supply line To fuel injection system
4. Banjo bolt - 23 Nm
5. Seal Replace
6. Fuel return line From fuel injection system
7. Double hose clamp Installation position, see «POSITION OF DOUBLE HOSE CLAMP»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__position-of-double-hose-clamp)
8. Connecting hose, lower
9. Fuel tank Removing and installing, see «FUEL TANK WITH ATTACHMENTS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-tank-with-attachments-removing-and)
10. Cross member For tank
11. 23 Nm
12. Securing strap Note different lengths
13. Securing strap Note different lengths

Position of cross brace

1. Bent-over ends -arrow- of cross brace -3- face downward.
2. Flexible packing pieces -2- must be installed between cross brace and securing straps -1-.

Position of double hose clamp

1. Screw clamps on double hose clamp -1-for lower connecting hose -2- should face downward at an angle of 60°. NOTE: There must be sufficient clearance between the double clamp and the vehicle body.

Fuel tank, draining

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

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

Special tools and required equipment

1. VAG1433 A

Scheme 1

Work sequence

1. Obtain code on vehicles with coded radio/integrated radio and navigation system.

See Caution before beginning repairs on the electrical system in FUEL SUPPLY SYSTEM .

1. With ignition switched off, disconnect battery Ground (GND) cable.
2. Briefly open fuel tank filler cap (to release pressure).
3. Remove sender for fuel gauge -G- (right). See «FUEL LEVEL SENSORS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-level-sensors-removing-and-installing) .
4. Extract remaining fuel in right-hand section of tank through opening for fuel level sender.
5. Remove fuel level sensor 2 -G169- (left side), see «REMOVING AND INSTALLING FUEL LEVEL SENSOR 2 -G169- (LEFT)»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__removing-and-installing-fuel-level-sensor) .
6. Extract remaining fuel in left-hand section of tank through opening for fuel level sensor 2 -G169-.
7. Install sender for fuel gauge -G- (right side) (see «INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) ) and fuel level sensor 2 -G169- (left side) (see «INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) ).

Fuel tank with attachments, removing and installing

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

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. VAG1383 A and VAG1359/2

Scheme 2

Removing

1. Obtain radio code on vehicles with coded radio/integrated radio and navigation system.

See Caution before beginning repairs on the electrical system in FUEL SUPPLY SYSTEM .

1. With ignition switched off, disconnect battery Ground (GND) strap.

Scheme 3

Scheme 4

Scheme 5

1. Drain fuel tank if necessary. See «FUEL TANK, DRAINING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-tank-draining) .
2. Remove covers for fuel level sensors and fuel delivery module on left and right sides under carpet in trunk.
3. Disconnect harness connectors on both fuel level sensors.
4. Move loose wiring clear and secure in trunk.
5. Remove both rear wheels.
6. Loosen clamps -arrows-.
7. Detach rear section of exhaust system and remove.
8. Remove both heat shields (in front of and behind rear axle).
9. Unbolt cover panel on underside of vehicle (left side) - arrows-.
10. Unbolt cover panel on underside of vehicle (right side) - arrows-.
11. Loosen parking brake cable retainers -arrows- and move parking brake cables clear.
12. Disconnect parking brake cables from brake calipers. See «PARKING BRAKE CABLES»(/audi/a8/d3-2002-2005/remont/mechanical-hydraulic/#disc-brakes__parking-brake-cables) .

1. Remove rear axle. See «SUSPENSION - REAR»(/audi/a8/d3-2002-2005/remont/suspension-rear/#suspension-rear) .

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Loosen double hose clamp at lower connecting hose and fuel filler pipe -arrow-. NOTE: The connecting hose should stay attached on the fuel tank flange.
2. Loosen hose clamps -2- on upper connecting hose between expansion tank fuel filler pipe -1-. (Scheme 11)
3. Slide upper connecting hose from expansion tank onto fuel filler pipe -1- and pull fuel filler pipe off fuel tank through opening in longitudinal member.
4. Mark breather hose -3-, -4- and -5- for installation.
5. Remove breather hoses -3-, -4- and -5- from pipes.
6. Unscrew fuel supply line -1- at fuel filter. (Scheme 12)
7. Disconnect fuel return line -2-.
8. Disengage connector -1- from bracket on tank cross member -2- (on left and right sides). (Scheme 13)
9. Unscrew nuts -arrow- on tank cross member (on left and right sides).
10. Remove cross member.
11. Loosen front securing straps -4- and -5-. (Scheme 14)
12. Position VAG1383 A transmission jack with VAG1359/2 plate under right-hand section of tank.
13. Support fuel tank and remove securing straps -1- and -2-. (Scheme 14)
14. With help of second technician, lower tank and guide breather lines through opening in longitudinal member. Breather pipes must not be bent.
15. Detach cross brace -3-. (Scheme 14)

Installing

Installation is carried out in the reverse order, when doing this note the following

Scheme 12

Scheme 13

Scheme 14

1. Make sure that wiring for ABS sensors is routed correctly.
2. Run breather lines -1- through opening in longitudinal member before bringing fuel tank into its final position. (Scheme 15)
3. Ensure that flexible packing piece -2- is installed in opening as illustrated.
4. Install fuel filler pipe -3- onto lower connecting hose on fuel tank.
5. When installing securing straps -1-, insert cross brace -3- with its bent-over ends facing downward -arrow-.
6. Make sure that flexible packing pieces -2- are installed.
7. Install double hose clamp -1- for connecting hose -2- so that screw clamps face downward at an angle of 60°.

Note. There must be sufficient clearance between the double clamp and the vehicle body.

1. Install subframe: See «SUSPENSION - REAR»(/audi/a8/d3-2002-2005/remont/suspension-rear/#suspension-rear) .

See Caution for connecting Telematics battery in FUEL SUPPLY SYSTEM .

1. Connect battery and input anti-theft code on vehicles with coded radio/ radio and navigation system See Radio operating instructions

1. Close windows fully using electric window switches.
2. Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic up and down function.
3. Set clock to correct time. TIGHTENING TORQUES: FUEL TANK Component Nm Securing straps to body 23 Rear cross member for fuel tank 23

Fuel delivery module and fuel level senders, removing and installing

The following list pertains to (Scheme 18).

1. Sealing ring Always replace When installing, install seal (dry) in opening in fuel tank
2. Fuel delivery module Removing and installing, see «FUEL DELIVERY MODULE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-removing-and-installing) Checking fuel pump (electrical test), see «FUEL PUMP, ELECTRICAL TESTING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-pump-electrical-testing) Checking holding/residual pressure: See «FUEL PRESSURE REGULATOR AND RESIDUAL FUEL PRESSURE, CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#multiport-fuel-injection-mfi-42l-v8-akb-aux-ays) .
3. Sealing plug Always replace
4. O-ring Always replace
5. Sender for fuel gauge -G- Checking resistance values, see «CHECKING RESISTANCE VALUES OF FUEL LEVEL SENDERS (TWO SENSORS)»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) Removing and installing, see «FUEL LEVEL SENSORS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-level-sensors-removing-and-installing)
6. Sealing washer Always replace
7. Spring
8. Flange for sender fuel gauge -G- Remove and install using 2012A spanner. See «FUEL LEVEL SENSORS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-level-sensors-removing-and-installing) . Turn clockwise to open; turn counter-clockwise to close
9. Banjo bolt - 23 Nm
10. Fuel return line From fuel injection system Clipped onto fuel tank
11. Fuel supply line To fuel filter Clipped onto fuel tank
12. Ring nut, 90 Nm Remove and install with special tool 3342
13. O-ring Always replace
14. Securing bolt, 20 Nm
15. Ring nut, 60 Nm Remove and install with special tool 3217
16. Sender -2- for fuel gauge -G169- Checking resistance values, see «CHECKING RESISTANCE VALUES OF FUEL LEVEL SENDERS (TWO SENSORS)»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) Removing and installing, see «REMOVING AND INSTALLING FUEL LEVEL SENSOR 2 -G169- (LEFT)»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__removing-and-installing-fuel-level-sensor)
17. O-Ring Always replace
18. Seal ring Always replace When installing, install seal (dry) in opening in fuel tank

Fuel supply system, function

The fuel tank employs a multichamber system.

The dual-stage electric fuel pump is located in a baffle housing (not shown in illustration).

The first stage of the fuel pump produces a stream of fuel (large arrow in illustration) which is directed to the three suction jet pumps -2-, -3- and -5-, where it is passed through a nozzle and thus accelerated. The accelerated jet of fuel draws off the surrounding fuel in the individual chambers and delivers it to the adapter plate -1- in the baffle housing via a system of lines.

The second stage of the electric fuel pump delivers the fuel from the baffle housing to the engine.

The first stage of the electric fuel pump, the system of suction jet pumps and the baffle housing together form a closed circuit inside the fuel tank.

For reliable starting, there must be fuel in the baffle housing at all times. To ensure that this is the case, even when an empty tank is topped off with a small quantity of fuel, the fuel filler pipe -4- goes directly into the adapter plate -1- on the baffle housing. In this way the fuel is always supplied directly to the fuel delivery module.

Scheme 15

Fuel pump, electrical testing

1. VAG1348/3A with VAG1348/3-2
2. VAG1526 A
3. VAG1594 A
4. VAG1715

Or

1. VAS5051 with VAS5051/1

Scheme 16

Scheme 17

1. Battery voltage not less than 12 V
2. Fuse S1 OK (in fuse box, blue fuse carrier ST4)
3. Fuel pump relay OK (on central electrics in E-box; passenger's footwell, relay position 6). Testing

See FUEL PUMP (FP) RELAY -J17- AND RELAY ACTIVATION, CHECKING .

1. Fuel filter OK
2. Ignition switched off

Scheme 18

Scheme 19

Scheme 20

1. Detach floor covering at front of passenger's footwell.
2. Unscrew knurled nut -1-. (Scheme 23)
3. Pull trim -2- out of clip -3- towards the rear.
4. Detach trim.
5. Disconnect fuse No. S1 out of fuse holder ST4 in fuse box. ST4 - blue fuse holder
6. Connect VAG1348/3A remote control with VAG1348/3-2 adapter cable to lower terminal of socket for fuse No. S1 in fuse holder ST4 -arrow 1-.
7. Connect clamp to battery (B+) supply (for example, socket of 60 Amp fuse -arrow 2- at top of fuse box).
8. Press remote control switch. Pump should start running audibly.

Note. The fuel pump runs very quietly. Where possible, avoid noisy surroundings for this test. If necessary, perform the test with a 2nd mechanic.

If pump does not start running

Scheme 21

Scheme 22

1. Remove cover for fuel level sender and fuel delivery module under carpet in trunk (right side).
2. Release and disconnect 4-pin connector -arrow-.
3. Connect multimeter (voltage range) between terminals 1 and 4.
4. Press remote control switch. Specification: approx. battery voltage

If the specification is not obtained

1. Locate and eliminate open circuit using wiring diagram diagram: See appropriate System Wiring Diagrams article.

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

1. Check current draw. See «CHECKING CURRENT DRAW»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__checking-current-draw) .
2. Remove fuel delivery module. See «FUEL DELIVERY MODULE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-removing-and-installing) .
3. Check if wiring between flange and fuel pump is disconnected or broken (test for continuity).

If no wiring malfunction is detected

1. Fuel pump is faulty. Replace fuel delivery module. See «FUEL DELIVERY MODULE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-removing-and-installing) .

Checking current draw

Test requirement

Scheme 23

1. Supply voltage for fuel pump OK, see «CHECKING VOLTAGE SUPPLY»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__checking-voltage-supply) Connect VAG1348/3A remote control with VAG 1348/3-2 adapter cable to lower terminal of socket for fuse No. S1 in fuse holder ST4 -arrow 1-. Connect clamp to battery (B+) supply (for example, socket of 60 A fuse -arrow 2- at top of fuse box). Connect vehicle diagnostic, testing and information system VAS5051 or multimeter VAG1715 to remote control cable via current pick-up clamp. Press remote control switch. Measure current draw of fuel pump.
2. Specification: approx. 8 A

If the specification is not obtained

Note. If the indicated current draw is 4 amps, this means the fuel pump is running dry (without fuel).

Scheme 24

1. To check the installation of fuel delivery module, see «INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .
2. For leak testing on baffle housing, see «LEAK CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__leak-checking)
3. To check the installation of fuel level sender 2, see «INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays)

Fuel pump delivery volume, checking

Scheme 25

1. VAG1348/3A with VAG1348/3-2
2. VAG1318/10
3. VAG1318/14
4. Measuring container (fuel-resistant)

Requirements for test

1. Battery voltage not less than 12 V
2. Fuel filter OK
3. Ignition switched off

Scheme 26

Scheme 27

Scheme 28

1. Remove floor matt at front of passenger's footwell.
2. Unscrew knurled nut -1-.
3. Remove trim -2- (-3- not installed)
4. Remove fuse No. S1 from fuse holder ST4 in fuse box. ST4 - blue fuse holder
5. Connect VAG1348/3A remote control with VAG1348/3-2 adapter cable to lower terminal of socket for fuse No. S1 in fuse carrier ST4 -arrow 1-.
6. Connect clamp to battery (B+) supply (for example, socket of 60 A fuse -arrow 2- at top of fuse box).
7. Remove engine cover panel.
8. Disconnect fuel return hose at fuel pressure regulator.

Scheme 29

1. Connect test hose -arrow- and hold end of hose in measuring container.
2. Operate remote control for 15 seconds (keep button pressed).
3. Compare the quantity of fuel delivered with specification.

Scheme 30

Note. The following text with asterisks (Scheme 35)

*) Minimum delivery cm 3 /15 seconds

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

1. Attach return hose and secure with new hose clamp.

Fuel delivery module, removing and installing

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

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

Scheme 31

Scheme 32

1. 2012 A wrench
2. 3342 ring nut wrench

1. Obtain radio code on vehicles with coded radio/integrated radio and navigation system.

See Caution before beginning repairs on the electrical system in FUEL SUPPLY SYSTEM .

Scheme 33

Scheme 34

1. With ignition switched off, disconnect battery Ground (GND) cable.
2. Remove cover for fuel level sender and fuel delivery module under carpet in trunk (right side).
3. Using 2012 A special tool, release flange for fuel level sender by turning it clockwise, detach flange and remove spring below it.
4. Using pliers, carefully lift fuel level sender slightly and disconnect connector -arrow-.

1. Secure harness connector to prevent it dropping back into fuel tank.
2. Pull out fuel level sender completely.
3. Extract remaining fuel in right-hand chamber through opening for fuel level sender.
4. Remove fuel level sensor 2 -G169- (left side). See «REMOVING AND INSTALLING FUEL LEVEL SENSOR 2 -G169- (LEFT)»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__removing-and-installing-fuel-level-sensor) .
5. Extract remaining fuel in left-hand chamber through opening for fuel level sender 2.
6. Disconnect harness connector -1-.

Scheme 35

Scheme 36

Scheme 37

1. Unscrew banjo bolt -2- for fuel supply line.
2. Disconnect fuel return line -3-.
3. Unscrew locking ring with special tool 3342.
4. Unscrew securing bolt -1- several turns, but do not remove.
5. Press securing bolt down firmly -arrow- to separate fuel delivery module from adapter plate in fuel tank. (Scheme 42)
6. Unscrew securing bolt completely and pull out.
7. Lift fuel delivery module slightly and pull off seal.
8. Lift fuel delivery module out of fuel tank by simultaneously pulling upward and turning clockwise.

Installation is carried out in the reverse order, when doing this note the following

Scheme 38

1. Before installing, check whether filler pipe -1- is clipped onto pipe retainer -arrow- on adapter plate -2-.

Note. The cut-away shows the fuel tank from the front. A flashlight and mirror can be used to check whether the filler pipe is clipped in properly. If the adapter plate and filler pipe are not clipped together it will not be possible to install the fuel delivery module properly, and the adapter plate can be damaged when installing.

Scheme 39

Scheme 40

1. Before inserting fuel delivery module, visually inspect baffle housing, lower section of baffle housing, and line connections for suction jet pumps.
2. Replace O-ring (item -4-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ) ) and sealing plug (item -3-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ).
3. Secure electrical connector for fuel level sender onto flange at top so that it does not drop into the tank during installation.
4. Install fuel delivery module as follows: Starting position: hose connection on top of flange pointing towards left side of vehicle (position 1). (Scheme 44)
5. Insert fuel delivery module into opening in fuel tank.
6. While inserting, rotate fuel delivery module about 180° counter-clockwise about its own axis -arrow-. Hose connection on top of flange then points toward right side of vehicle (position 2). (Scheme 44) The arrow markings -2- and -3- should line up.
7. Hold fuel delivery module in this position about 40 mm above opening in the fuel tank, as illustrated. NOTE: The cut-away shows the fuel tank from the front.
8. Press fuel delivery module downward. The output line (motion stream) from the fuel delivery module to the suction jet pumps will then be pressed down into the funnel on the adapter plate -arrows-.

It is not possible to see from the outside whether the components have been assembled properly, so check as follows before finally securing in place.

1. The flange of the fuel delivery module should install flat and square on the opening in the fuel tank.
2. The securing bolt should slip easily and without obstruction into the thread in the adapter plate, and should screw in easily and smoothly.

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. After checking the installation, lift out the fuel delivery module slightly and install the flange seal in the rim of the opening on the fuel tank.
2. Insert fuel delivery module again.
3. Install new O-ring -1- on securing bolt -2-.
4. Tighten securing bolt finger-tight (to start with).
5. Install locking ring and tighten to 90 Nm using special tool 3342.
6. Tighten securing bolt to 23 Nm.
7. Tighten banjo bolt -2- for fuel supply line to 23 Nm. (Scheme 48)
8. Connect fuel return hose -3- and secure with new hose clamp.
9. Connect harness connector -1-.
10. Replace O-ring on fuel level sender (item -4-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ) and sealing plug (item -3-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ).
11. Insert fuel level sender.
12. Reconnect electrical connector -arrow- when sliding fuel level sender back into tank.
13. Install pressure spring.
14. Using special tool 2012 A, carefully tighten flange for fuel level sender by turning it counter-clockwise as far as it will go.

See Caution for connecting Telematics battery in FUEL SUPPLY SYSTEM .

1. Connect battery and enter anti-theft code on vehicles with coded radio/ radio and navigation system

See Radio operating instructions

1. Close windows fully to top using electric window switches.
2. Then operate all electric window switches again for at least one second in the "Close" position to activate the automatic up and down function.
3. Set clock to correct time.
4. Check fuel delivery module for leaks. See «LEAK CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__leak-checking) .

Leak checking

Test requirement

1. Fuel tank drained.

1. Fill fuel tank with 5 liters (1.1 Gallon) of gasoline.
2. Carry out road test of at least 10 km (6 miles) (take spare canister of fuel).
3. Leave vehicle standing overnight. If the engine starts readily (without problem) after the vehicle has been standing for this period, this means the fuel delivery module is not leaking.
4. Fill up fuel tank and road test vehicle for final test drive.

If the engine does not start

1. Check whether fuel delivery module has been installed properly. See «INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .

Fuel level senders, checking

Special tools and required equipment

1. VAG1526 A
2. VAG1594 A

Note. Testing signal from fuel level sender: See SIGNAL FROM SENDER FOR FUEL GAUGE -G-, CHECKING Observe safety precautions. See SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY SYSTEM . Before removing the two fuel level senders, use an ohmmeter to check whether the resistance values of the sensors correspond with the fuel gauge reading. The two sensors are wired in series, therefore, the two resistance values must be added together in order to check the fuel gauge reading.

Scheme 46

Scheme 47

1. Remove covers for fuel level senders and fuel delivery module under carpet in trunk on left and right sides.
2. Connect multimeter to terminals 2 and 3 on right sensor.
3. Release and disconnect 2-pin harness connector on left sensor.
4. Connect multimeter between terminals 1 and 2.
5. Add resistance values of two sensors together and compare with following table.

Note. The left chamber of the fuel tank is always drained first. When the tank is 1/4 full, you should therefore obtain a resistance of 80-100 Ohm at the right sensor and a resistance of 40-44 Ohm at the left sensor. A resistance of 40-44 Ohm at the left sensor means that the left-hand chamber is completely empty.

FUEL LEVEL SENDERS RESISTANCE SPECIFICATIONS

Note. In order to test the maximum and minimum values for "tank full" and "tank empty", remove both fuel level sensors (see FUEL LEVEL SENSORS, REMOVING AND INSTALLING and REMOVING AND INSTALLING FUEL LEVEL SENSOR 2 -G169- (LEFT) ) and pivot or slide the floats of the two sensors all the way to their top and bottom positions.

When the fuel level sender is removed, the float will travel further and the specifications are

FUEL LEVEL SENDERS RESISTANCE SPECIFICATIONS - SENDER REMOVED FROM TANK

Fuel level sensors, removing and installing

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

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. Obtain radio code on vehicles with coded radio/integrated radio and navigation system.

See Caution before beginning repairs on the electrical system in FUEL SUPPLY SYSTEM .

1. With ignition switched off, disconnect battery Ground (GND) strap.

Scheme 48

1. Spanner 2012 A

Scheme 49

Scheme 50

1. Remove cover for fuel level sender and fuel delivery module under carpet in trunk (right side). NOTE: Fuel hoses and electrical connectors and do not have to be disconnected.
2. Using special tool 2012 A, open flange for fuel level sensor by turning it clockwise, detach flange and take out the spring below it.
3. Using pliers, carefully lift fuel level sender slightly and disconnect harness connector -arrow-.

1. Secure harness connector to prevent it from dropping back into fuel tank.
2. Remove fuel level sender completely.

Installation is carried out in the reverse order, when doing this note the following

Scheme 51

Scheme 52

1. Replace O-ring on fuel level sender (item -4-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ) and sealing plug (item -3-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ).
2. Insert fuel level sender.
3. Reconnect harness connector -arrow- when sliding fuel level sender back into tank.
4. Install pressure spring.
5. Using special tool 2012 A, carefully tighten flange for fuel level sender by turning it counter-clockwise as far as it will go.

See Caution for connecting Telematics battery in FUEL SUPPLY SYSTEM .

1. Connect battery and input anti-theft code on vehicles with coded radio/ radio and navigation system. See Radio operating instructions

1. Close windows fully using electric window switches.
2. Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic up and down function.
3. Set clock to correct time.

Removing and installing Fuel Level Sensor 2 -G169- (left)

1. 3217 Ring nut spanner

Scheme 53

Scheme 54

1. Drain fuel tank. See «FUEL TANK, DRAINING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-tank-draining) .
2. Remove cover for fuel level sender (left side) under carpet in trunk.
3. Disconnect harness connector from sensor.
4. Unscrew ring nut with special tool 3217.
5. Carefully remove (pull out) sensor.

Scheme 55

Scheme 56

Scheme 57

1. Insert left fuel level sender. Make sure fuel lever sensor -2- is correctly installed in bracket -1-. NOTE: The sensor should press down the retainer which is attached to the hoses for the suction jet pump on the left side of the tank. This presses the suction jet pump against the bottom of the tank. If this is not the case, the left-hand chamber of the tank will not be emptied properly and the engine will cut out due to fuel starvation when there are still 10 - 14 liters (2.6 - 3.7 Gallons) of fuel left in the tank. To insert the sensor, look down one side (arrow) into the tank. When sensor has been engaged properly in the retainer, press it into opening and turn it until the two arrows line up exactly. Tighten ring nut to 60 Nm. See Caution for connecting Telematics battery in «FUEL SUPPLY SYSTEM»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) . Connect battery and input anti-theft code on vehicles with coded radio/ radio and navigation system See Radio operating instructions Close windows fully using electric window switches. Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic up and down function. Set clock to correct time.

Fuel filler neck with expansion tank, component overview

Note. Observe safety precautions when working on fuel expansion tank. See SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY SYSTEM .

The following list pertains to (Scheme 65).

1. Ground (GND) connection Installation position, see «INSTALLATION POSITION OF GROUND (GND) CONNECTION»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__installation-position-of-ground-gnd-connection) Make sure that connector is seated correctly on metal ring of filler neck After installation Check electrical connection between metal ring and body GND with ohmmeter. Specification: approx. 0 Ohm Check connection of body GND next to battery
2. Vent line From fuel tank
3. Vent line From fuel tank
4. Vent line From gravity valve - 9 - To EVAP canister valve, see «INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays)
5. Vent line From fuel tank To vent valve - 7
6. Adapter
7. Vent valve Removing and installing, checking, see «BLEED VALVE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__bleed-valve-removing-and-installing)
8. O-Ring Not available separately as replacement part
9. Gravity valve Welded to expansion tank Checking, see «GRAVITY VALVE, CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__gravity-valve-checking)
10. Expansion tank Removing and installing, see «FUEL FILLER NECK WITH EXPANSION TANK, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-filler-neck-with-expansion-tank)
11. Rubber cup
12. Tank filler cap
13. Sealing ring Replace if damaged
14. Lock ring
15. Six-point screw, 3
16. Overflow hose
17. Connecting hose To remove expansion tank, push connecting hose over fuel filler hose - 18 -.
18. Fuel filler hose

Installation position of Ground (GND) connection

1. Make sure that harness connector -2- for Ground (GND) connection is properly seated on metal ring (Ground clamp) -1- on fuel filler neck.

1. Specification: approx. 0 ohm

If the specification is not attained

Scheme 58

1. Check wiring.
2. Check that Ground (GND) connection is properly connected to the Ground (GND) point next to the battery.

Bleed valve, removing and installing

1. Expansion tank removed

Scheme 59

1. To remove unclip valve from expansion tank.
2. Before installing bleed valve remove fuel filler cap.
3. Bleed valve checking: Lever in rest position: Valve closed Lever pressed in direction of arrow: Valve open

Gravity valve, checking

Note. The Gravity valve -2- can only be replaced with the expansion tank as one unit.

Checking

1. Expansion tank -3- removed

Scheme 60

1. Hold expansion tank in installation position (as shown in illustration) It must be possible to blow into port -1
2. Tip expansion tank 45° degree. It must NOT be possible to blow into port -1

If test requirements are not obtained

1. Replace expansion tank.

Fuel filler neck with expansion tank, removing and installing

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

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

1. Obtain radio code on vehicles with coded radio/integrated radio and navigation system.

See Caution before beginning repairs on the electrical system in FUEL SUPPLY SYSTEM .

1. With ignition switched off, disconnect battery Ground (GND) strap.

1. Drain fuel tank. See «FUEL TANK, DRAINING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-tank-draining) .
2. Remove right rear wheel.
3. Remove right rear wheel housing liner: See «REAR WHEELHOUSING LINER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/mirrors/#exterior-equipment__rear-wheelhousing-liner-removing-and-installing) .

Scheme 61

Scheme 62

1. Clean area around fuel filler neck.
2. Open fuel filler cap, unclip rubber cup (around filler neck).
3. Press rubber cup toward inside.
4. Loosen hose clamps -3- at upper connection hose between expansion tank and fuel filler hose -1-. (Scheme 69)
5. Push upper connection hose from expansion tank over fuel filler hose -1-. (Scheme 69)
6. Mark vent hoses -2-, -4-, -5- and -6- for installation.
7. Disconnect vent hoses -2-, -4-, -5- and -6- from lines. (Scheme 69)
8. Unscrew 3 screws -arrows-.
9. Carefully lower expansion tank slightly.

See Caution before beginning repairs on the electrical system in FUEL SUPPLY SYSTEM .

Scheme 63

1. Disconnect Ground (GND) cable -2- at metal ring (Ground clamp) of fuel filler neck.
2. Remove filler neck with expansion tank.
3. Unclip over flow hose.

Installation occurs in reverse order, observe the following

Note. Make sure that ventilation hoses are correctly installed (not kinked) For the installation of band clamps it is recommended to use the VAG1921 pliers.

1. Make sure that electrical connector -2- for Ground (GND) connection is properly seated on metal ring (Ground clamp) -1- on fuel filler neck.

1. Specification: approx. 0 ohm

If the specification is not attained

Scheme 64

1. Check wiring.
2. Check that Ground (GND) connection is properly connected to the Ground (GND) point next to the battery.

1. Connect battery and enter anti-theft code on vehicles with coded radio/ radio and navigation system See Radio operating instructions

1. Close windows fully to top using electric window switches.
2. Then operate all electric window switches again for at least one second in the "Close" position to activate the automatic up and down function.
3. Set clock to correct time. TIGHTENING TORQUE: FUEL FILLER NECK WITH EXPANSION TANK Component Nm Fuel filler neck with expansion tank on body 5

Fuel filter, replacing

The following list pertains to (Scheme 73).

1. 2 Nm
2. Bracket For fuel filter
3. Fuel filter Flow direction is marked by an arrow Do not interchange connections
4. Sealing washer Always replace
5. Banjo bolt - 23 Nm
6. Fuel supply line From fuel tank
7. Fuel supply line To metering pump for auxiliary heater
8. Banjo bolt - 23 Nm
9. Sealing washer Always replace
10. Fuel supply line To fuel rail
11. Sealing washer Always replace

EVAP canister, component overview

The following list pertains to (Scheme 74).

1. Cover For EVAP canister
2. Vent line To EVAP canister purge regulator valve -N80
3. Vent line From gravity valve to expansion tank
4. Connection hose Leak detection pump/EVAP canister
5. Evaporative Emission (EVAP) canister purge regulator valve -N80- Location: below and within spare wheel housing Removing and installing, see «EVAP CANISTER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__evap-canister-removing-and-installing)
6. Socket
7. Rubber grommet
8. Bolt (Stud) - 16 Nm
9. Nut - 9 Nm

EVAP canister, removing and installing

Note. Check seal integrity; perform tank leak diagnosis. See EVAP SYSTEM, AUTOMATIC LEAK TESTING .

1. Remove cover for EVAP canister at bottom of (below) spare tire well -arrows-.
2. Loosen hose connections 1 to 3 on vent lines.
3. Loosen studs -arrows-.

Installation is performed in the reverse order of removal, during installation note the following

TIGHTENING TORQUE: EVAP CANISTER

EVAP system leak detection circuit diagram

The following list pertains to (Scheme 77).

1. Throttle valve control module -J338
2. Evaporative Emission (EVAP) canister purge regulator valve -N80- Location: In engine compartment Checking: See «EVAPORATIVE EMISSION (EVAP) CANISTER PURGE REGULATOR VALVE -N80-, CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#multiport-fuel-injection-mfi-42l-v8-akb-aux-ays) .
3. Vent line From EVAP canister to EVAP canister purge regulator valve -N80- Installation position: right side under floor pan
4. Vent line To gravity valve on expansion tank
5. EVAP canister Location: Inside bottom of spare wheel well
6. Connection hose LDP/EVAP canister Pressure side
7. Leak Detection Pump (LDP) -V144- Vacuum operated Location: In wheel housing left rear, beneath wheel housing liner
8. Air filter For LDP pump Location: Arrow on filter housing points to LDP 7
9. Vacuum line/hose LDP/intake manifold, front

EVAP system leak detection system, function

The leak detection system can recognize leaks in the entire fuel system, including the main fuel tank, the EVAP canister and EVAP canister purge regulator valve -N80-.

On the mechanical side, the leak detection system consists of a vacuum-operated diaphragm pump (Leak Detection Pump, or LDP) with a reed contact on the pump diaphragm rod. The pump receives vacuum from the intake manifold.

1. If the leak detection system is triggered, the diaphragm pump pressurizes the fuel system to 20-30 mbar.
2. If the specified pressure is reached, the pump diaphragm remains extended and the reed contact remains in the "Open" position.
3. If the pressure drops (i.e. there is a leak) the diaphragm moves back and the reed contact closes.
4. During diagnosis, first there is a measurement of whether the reed contact closed within 10 seconds. If this does not occur, the tank system is then sealed.
5. If, however, the reed contact closes within 10 seconds, there is a leak. In this case, the pump continues to cycle for four more strokes. The Engine Control Module (ECM) measures the time for each of these four strokes until the next time the reed contact closes. The Engine Control Module (ECM) recognizes if the leak is larger than 1mm diameter and the ECM can differentiate between "small" and "large" leaks.
6. Leak detection is automatically triggered shortly after each engine start, see «EVAP SYSTEM, AUTOMATIC LEAK TESTING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__evap-system-automatic-leak-testing) . If there is an incorrect measurement, a malfunction is stored in the DTC memory. A warning will appear on the instrument panel if the malfunction has occurred during two successive drives. Also, the leak detection can also be activated using the Vehicle Diagnostic, Testing and Information System VAS5051 or 1551 scan tool, see «EVAP SYSTEM, LEAK TESTING USING VAS5051 OR VAG1551»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__evap-system-leak-testing-using-vas5051) .

EVAP system, automatic leak testing

The ECM performs at certain intervals a tank leak test with the engine running, e.g. shortly after the engine is started.

A leak test can be evaluated using the VAS5051 or the VAG1551 scan tool, using the "Read Measuring Value Block" function. See EVAP SYSTEM, LEAK TESTING USING VAS5051 OR VAG1551 .

If the system is OK

Scheme 65

1. This is displayed in display group 071

If the automatic tank leak test was aborted due to incorrect test results

Scheme 66

1. This is displayed in display group 071

If the system is not OK

Scheme 67

1. "Syst.n.OK" appears in display group 071 (example)
2. In addition, a DTC will be stored in DTC memory (example): NOTE: The tank leak test with the Vehicle Diagnostic, Testing and Information System VAS5051 or VAG1551 will not be hindered by the automatic tank leak test.

EVAP system, leak testing using VAS5051 or VAG1551

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

Observe safety precautions. See RULES FOR CLEANLINESS .

Test requirements

1. Parking brake applied
2. Gear selector lever in P or N
3. No DTCs in DTC memory
4. Electrical consumers switched off (radiator fan must NOT run during test)
5. A/C switched off
6. Intake Air Temperature (IAT) less than 90° C => display group 004, display field 4.
7. Coolant Temperature less than 95° C => display group 004, display field 3.
8. Throttle valve angle less than 10° => display group 003, display field 3.

Scheme 68

1. Connect VAS5051 with diagnostic cable VAS5051/1 or VAG1551 scan tool with diagnostic cable VAG1551/3A. NOTE: The following description only explains implementation of On Board Diagnostic (OBD) using VAG1551 scan tool. When using VAS5051, observe the tester's instructions for use.
2. Start engine and run at idle.
3. Press button 1 to select "Rapid data transfer" operating mode 1.

Indicated on display

Scheme 69

1. Press buttons -0- and -1- to select "Engine electronics" and press -Q- button to confirm input.
2. Press --> -button.

Indicated on display

Scheme 70

1. Press buttons -0- and -8- to select "Read Measuring Value Block" and press -Q- button to confirm input.

Indicated on display

Scheme 71

1. Press buttons -0-, -7- and -1- to select display group number 071 and press -Q- button to confirm input.

Indicated on display

Scheme 72

Note. If "Reed cl" (closed) is displayed, continue test. "Abort" does not always appear on display. If display indicates "Reed open", briefly open and close fuel filler cap to release pressure from fuel tank. This will close the reed contact. Continue test as follows

1. Press button -4- to select "Basic setting" operating mode 4.

If indicated on display

Scheme 73

The Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-will be opened briefly to release pressure (purge) in system.

Then the Leak Detection Pump (LDP) -V144- will be activated, the process will last approx. 60 seconds.

Indicated on display

Scheme 74

System is performing a system test. Then the LDP -V144 will start up. It will shut off when the pump time has run out. The process will last about 60 seconds.

Indicated on display

Scheme 75

Measuring phase begins. LDP is switched off and the Engine Control Module (ECM) checks whether the reed contacts closes within 10 seconds

If reed contact does not close within 10 seconds

Indicated on display

Scheme 76

System is sealed, test is terminated

1. Press --> button.
2. Press buttons -0- and -6- to select "End Output" and press -Q- button to confirm input.

If reed contact does close within 10 seconds

The Leak Detection Pump (LDP) -V144 will pump four additional strokes for an additional measurement. The Engine Control Module (ECM) compares the time required for these four strokes and time closure of the reed contact.

Indicated on display. System has a small leak (smaller than 1 mm in diameter).

Scheme 77

Indicated on display. System recognized a large leak.

Scheme 78

1. Press --> button.
2. If the system has detected a small or large leak, check fuel supply system and tank ventilation system for leaks and repair as necessary. See «CHECKING FUEL SUPPLY AND TANK VENTILATION SYSTEM FOR LEAKS»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__checking-fuel-supply-and-tank-ventilation) .
3. After repairs are completed, repeat leak test. See «EVAP SYSTEM, LEAK TESTING USING VAS5051 OR VAG1551»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__evap-system-leak-testing-using-vas5051) .

Checking fuel supply and tank ventilation system for leaks

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

1. Switch ignition off.
2. Check if fuel filler cap was completely closed for test.
3. Check if seal of fuel filler cap is damaged, replace if necessary.
4. Remove covers for fuel level sensors and fuel delivery module on left and right side under carpet in trunk.
5. Check whether seals under connection flanges are OK and ring nuts are properly tightened. Also check if fuel line connections are tight. NOTE: Observe installation notes for connector flanges. See «INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .
6. Check whether O-rings for fuel level sender (item -4-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ) and securing bolt (item -14-, see «FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__fuel-delivery-module-and-fuel-level) ).
7. Visually check all lines and hose connections of tank ventilation system and replace leaky lines: Line from fuel tank to fuel expansion tank. Line EVAP canister to EVAP canister purge regulator valve (in engine compartment). Lines from EVAP canister to Leak Detection Pump (LDP) (under left rear wheelhousing liner). Line from fuel expansion tank to EVAP canister (under cover for EVAP canister). Lines from EVAP system (tank ventilation system). Fuel lines to engine. NOTE: Leaks at lines and components of fuel supply system can sometime be located using a non-flammable, environmentally sound leak detection spray. For this, initiate leak test several times in sequence to build pressure in the system. Leaks can be detected via bubbles forming at the leak.
8. Visually check components of fuel supply system and EVAP system. Fuel tank EVAP canister Leak Detection Pump (LDP) -V144- Evaporative Emission (EVAP) canister purge regulator valve -N80

Note. Because of the shape or function of these components it is not always possible to detect leaks by applying spray. It may be necessary to clamp off the relevant component using 3094 hose clamp and initiate the leak detection diagnostic. If the leak is no longer detected, the component that was clamped off if faulty. If the clamp is directly on the diagnostic pump and a leak is still detected, then the diagnostic pump itself is leaking. Checking Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-: See EVAPORATIVE EMISSION (EVAP) CANISTER PURGE REGULATOR VALVE -N80-, CHECKING .

Leak Detection Pump (LDP) -V144-, overview

The following list pertains to (Scheme 92).

1. Line
2. Vacuum line To EVAP canister
3. 8 Nm
4. Support bolt
5. 5 Nm
6. Bracket On LDP - 8
7. Vacuum line To intake manifold
8. Leak Detection Pump (LDP) -V144- Location: In wheel housing left rear behind wheel housing liner
9. Bracket On Body
10. Air filter For Leak Detection Pump (LDP) -V144- Location: Arrow on filter housing points to LDP - 8
11. Cable tie strap

Special tools and equipment

1. VAG1526 A
2. VAG1527 B
3. VAG1594 A
4. VAG1598/31
5. VAS5051 with VAS5051/1 or
6. VAG1551 with VAG1551/3 A

Scheme 79

1. Connect VAS5051 with diagnostic cable VAS5051/1 or VAG1551 scan tool with diagnostic cable VAG1551/3A.

Note. The following description only explains implementation of On Board Diagnostic (OBD) using VAG1551 scan tool. When using VAS5051, observe the tester's instructions for use.

Scheme 80

Indicated on display

1. Operating modes 1 and 2 are displayed alternately

1. Switch ignition on.
2. Press button 1 to select "Rapid data transfer" operating mode 1.

Indicated on display

Scheme 81

1. Press buttons -0- and -1- to select "Engine electronics" and press -Q- button to confirm input.
2. Press --> button.

Indicated on display

Scheme 82

1. Press button -0- and -3- to select function "output Diagnostic Test Mode".

Indicated on display

Scheme 83

1. Confirm input with -Q- button.

Indicated on display (EVAP canister purge regulator valve -N80-)

Scheme 84

1. Press --> button until following display is indicated

Indicated on display

Scheme 85

The Leak Detection Pump (LDP) -V144- will be activated for approx. 1 minute.

Note. Operating noise of Leak Detection Pump (LDP) is audible at left rear wheelhousing.

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

1. Switch ignition off.
2. Remove Leak Detection Pump (LDP) -V144- (see «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) ), and disconnect harness connector.
3. Check the internal resistance of the LDP, see «CHECKING INTERNAL RESISTANCE»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__checking-internal-resistance) .
4. Check the voltage supply for the LDP, see «CHECKING VOLTAGE SUPPLY»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .
5. Check the output wire of the LDP, see «CHECKING OUTPUT WIRE»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .

Checking internal resistance

1. Connect multimeter for resistance measurement as follows. LEAK DETECTION PUMP RESISTANCE MEASUREMENT LDP -V144 terminals Specified value 1 + 3 640 - 720 ohm 2 + 3 15 - 17 ohm

Scheme 86

If specified values are not obtained

1. Replace Leak Detection Pump (LDP) -V144-. See «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .

If specified values are obtained

1. Check voltage supply at harness connector of Leak Detection Pump (LDP). See «CHECKING VOLTAGE SUPPLY»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .

Checking voltage supply

Note. Voltage supply for the Leak Detection Pump (LDP) runs via the Fuel Pump (FP) relay.

Test requirement

1. Fuse for Leak Detection Pump (LDP) OK

1. Disconnect harness connector at LDP.
2. Connect VAG1527 B voltage tester as follows: LEAK DETECTION PUMP CIRCUIT TEST - VOLTAGE SUPPLY Electrical harness connector terminal Measure to 3 Engine Ground (GND)
3. Operate starter briefly.

LED must light.

If LED does not light

Scheme 87

1. Check wire connection from terminal 3 via fuse to Fuel Pump (FP) relay for open circuit.

See appropriate System Wiring Diagrams article.

1. Repair open circuit if necessary.

If wire connection is OK.

1. Check Fuel Pump (FP) relay. See «FUEL PUMP (FP) RELAY -J17- AND RELAY ACTIVATION, CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#multiport-fuel-injection-mfi-42l-v8-akb-aux-ays__fuel-pump-fp-relay-j17-and) .

Scheme 88

Scheme 89

1. Connect VAG1527 B voltage tester as follows: LEAK DETECTION PUMP CIRCUIT TEST - OUTPUT WIRE Electrical harness connector terminal Measure to 2 B+
2. Initiate output Diagnostic Test Mode (DTM). See «INITIATE OUTPUT DIAGNOSTIC TEST MODE (DTM) AS FOLLOWS.»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .
3. Press --> button until following display is indicated

Indicated on display

LED must light.

If LED does not light

Scheme 90

Scheme 91

Scheme 92

Scheme 93

1. Switch ignition off.
2. Remove Phillips head screws -1- from the E-box cover. (Scheme 106)
3. Unclip water box cover -2- from the bulkhead -arrows-.
4. Remove water box cover.
5. Pry fresh air intake grid up to remove Phillips head screws from rear of cover -right arrow-.
6. Remove rest of screws.
7. Remove E-box cover.
8. Disengage locking lugs and disconnect harness connectors from Engine Control Module (ECM). NOTE: The connector for the ECM can only be disconnected or connected with the ignition switched off.
9. Connect VAG1598/31 test box to multi-pin harness connectors. The Ground (GND) clip must be clipped to Ground (GND). The ECM must not be attached.
10. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+. LEAK DETECTION PUMP CIRCUIT TEST - OPENS/SHORTS Electrical harness connector terminal VAG1598/31 test box socket 2 25
11. Repair open circuit or short circuit if necessary. If no malfunction is identified, but the Leak Detection Pump (LDP) does not function during the output Diagnostic Test Mode (DTM): Replace Leak Detection Pump (LDP) -V144-. See «LEAK DETECTION PUMP (LDP) -V144-, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) If LED does not blink, but wiring is OK: Replace Engine Control Module (ECM). See «MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- (WITHOUT METAL ANTI -THEFT HOUSING), REPLACING»(/audi/a8/d3-2002-2005/remont/fuel-system/#multiport-fuel-injection-mfi-42l-v8-akb-aux-ays__motronic-engine-control-module-ecm-j220) or «MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- (WITH METAL ANTI -THEFT HOUSING), REPLACING»(/audi/a8/d3-2002-2005/remont/fuel-system/#multiport-fuel-injection-mfi-42l-v8-akb-aux-ays__motronic-engine-control-module-ecm-j220).

After completing work

1. Generate readiness code. See «READINESS CODE, GENERATING»(ref-216437-S25676712792006020800000) .

If there is no DTC stored

1. Go to «CHECKING INPUT WIRE»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .

Scheme 94

1. Switch ignition off.
2. Connect VAG1598/31 test box to multi-pin harness connectors. See «CHECKING OUTPUT WIRE»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .
3. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+. LEAK DETECTION PUMP CIRCUIT TEST - INPUT WIRE Electrical harness connector terminal VAG1598/31 test box socket 1 80
4. Repair open circuit to short circuit if necessary.

After completing work

Scheme 95

1. Generate readiness code. See «READINESS CODE, GENERATING»(ref-216437-S25676712792006020800000) .

Scheme 96

1. Remove left rear wheel.
2. Remove left rear wheelhousing liner. See «WHEELHOUSING LINER»(/audi/a8/d3-2002-2005/remont/mirrors/#exterior-equipment).
3. Disconnect hoses -1-, -3- and -4-. (Scheme 113)
4. Unscrew nuts -arrows-.
5. Switch ignition off.
6. Remove LDP and disconnect harness connector -2-.

Installation is the reverse of removal, note the following

Scheme 97

1. Secure hoses -3- and -4- in lower wheelhousing using cable tie-wrap.

TIGHTENING TORQUE: LEAK DETECTION PUMP

Description

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

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

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

Test EVAP system using Leak Detection Pump (LDP) -V144- (m.y. 1998 and later)

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

For vehicles with LDP

1. Perform leak test using VAS 5051 Scan Tool and Basic Setting mode. See «LEAK DETECTION PUMP (LDP) -V144-, CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .

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

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

If "System OK" after re-test

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

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

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

Perform EVAP tester self-test

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

Scheme 98

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

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

Scheme 99

1. Verify that valve on EVAP tester nitrogen cylinder is open and that cylinder has sufficient pressure before continuing.
2. Turn fine adjust regulator knob (arrow) until gauge reads 14 in. of water; tighten lock nut.

Note. If gauge still does not read within above range, contact K-Line Customer Service - Technical Support for additional instructions before continuing.

1. Check flow meter -4-. (upper illustration). Meter must indicate no flow.
2. Turn control valve to "Hold" position.
3. Check gauge. Gauge must hold pressure

If gauge leaks down

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

If gauge continues to leak down

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

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

Calibrate KLI9210 Tester

Determine vehicle leak threshold

To m.y. 2000: leak threshold 0.040 in.

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

Scheme 100

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

Scheme 101

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

If no flow is indicated

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

If flow is indicated

1. Replace fuel cap and re-test.

If new fuel cap shows no flow

1. Repeat Leak Test, with new fuel cap installed, using VAS 5051 and Basic Settings mode. See «LEAK DETECTION PUMP (LDP) -V144-, CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) .

If Leak Test shows "System OK"

1. Perform quality check and return vehicle to customer.

Test LDP -V144- for internal leaks

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

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

If VAS 5051 indicates "System not OK"

1. Replace LDP and repeat test. If VAS 5051 indicates "System OK" after LDP is replaced and test result is verified
2. Perform quality check and return vehicle to customer.

Test EVAP System

Also, see EVAP SYSTEM LEAK DETECTION SYSTEM, FUNCTION .

If vehicle is not LDP-equipped

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

If vehicle is LDP-equipped

1. Plug or clamp LDP inlet (filter side) using Special Tool No. 3094 or equivalent.
2. Attach fuel cap adapter to filler neck (arrow) and test hose to adapter.
3. Turn control valve from "Hold" to "Test".
4. Allow fuel system to pressurize.

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

If fuel system pressurization does not stabilize

Scheme 102

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

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

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

Scheme 103

1. Clamp off hose (arrow) leading from EVAP purge regulator valve -N80- to intake manifold (pictured: AHA engine in A6).

If flow stops

1. Replace EVAP purge regulator valve -N80- and repeat test before continuing.

If meter indicates no flow after test

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

If flow continues, proceed as follows

Method 1: Locate leak with smoke generator

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

Method 2: Locate leak with ultrasonic tester

General search: tester only

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

If leak cannot be located

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

Scheme 104

If flow stops

1. Reconnect EVAP lines to search area that was isolated

If leak or source of fuel odor cannot be found

1. Contact Audi Dealer Technician Helpline.

When leak has been located

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

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

Accelerator pedal linkage (vehicles with electronic throttle control), servicing

The following list pertains to see scheme 122.

1. 5 Nm
2. Cap
3. 8 Nm
4. Bracket
5. 8 Nm
6. Spring washer
7. Cable cam Installation position, see «ACCELERATOR PEDAL POSITION SENSOR, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays)
8. Throttle Position (TP) sensor -G79- Adjusting, see «ACCELERATOR PEDAL POSITION SENSOR, ADJUSTING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) Removing and installing, see «ACCELERATOR PEDAL POSITION SENSOR, ADJUSTING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays)
9. Allen key bolt - 8 Nm
10. 10 Nm
11. Accelerator pedal
12. Kick down switch -F8- Checking Kick-Down switch, see «KICK-DOWN SWITCH, CHECKING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays) , or «ON BOARD DIAGNOSTIC (OBD) - 5 SPD. AUTOMATIC TRANSMISSION (01L, AWD)»(/audi/a8/d3-2002-2005/remont/automatic-trans/#on-board-diagnostic-obd-5-spd-automatic-transmission-01l-awd) . When removing, carefully lift safety latch and turn stop counter-clock wise.
13. Plate

Scheme 105

Scheme 106

1. Remove knee protection bar on drivers side See «KNEE BAR AND BRACKET, DRIVER SIDE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-equipment__knee-bar-and-bracket-driver-side).
2. Remove left front floor mat.
3. Unscrew nut -3-.
4. Unscrew Allen bolt -2-. see scheme 123
5. Remove A-pillar trim bottom left -1-.
6. Remove left air channel below instrument cluster.
7. Disconnect operating rod -1- from accelerator pedal -2- -arrow-.
8. Unscrew accelerator pedal position sensor.

Installation is the reverse of removal; during installation observe the following.

Scheme 107

1. Install cable cam see scheme 125
2. Install accelerator pedal position sensor together with cable cam. Cable cam with operating rod Bracket for accelerator pedal position sensor
3. Adjust accelerator pedal position sensor. See «ACCELERATOR PEDAL POSITION SENSOR, ADJUSTING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays).

1. VAS5051 and VAS5051/1 or
2. VAG1551 and VAG 1551/3 A

Scheme 108

Scheme 109

1. Connect VAS 5051 with diagnostic cable VAS 5051/1 or VAG1551 with diagnostic cable VAG1551/3A.

Note. The following description only covers the procedure for performing On Board Diagnostic using the VAG1551 scan tool. If using the VAS5051, follow the operating instructions supplied with the equipment.

Indicated in display

Scheme 110

1. appears alternately

1. Switch ignition on.
2. Switch on printer with Print button (lamp in button lights up).
3. Press button -1- for "Rapid data transfer."

When this display appears

Scheme 111

1. Press buttons -0- and -1- for address word "Engine electronics" and confirm entry with -Q- button.

Indicated on display: control module identification (example).

Scheme 112

1. Press --> button twice.

When this display appears

Scheme 113

1. Input "08" to select function "Read Measuring Value Block" and confirm entry with -Q- button.

When this display appears

Scheme 114

1. Press buttons -0-, -6- and -2- for display group number 062 and confirm entry with -Q- button.

When this display appears

Scheme 115

1. Check display in display field 3 (accelerator pedal position).
2. Press accelerator pedal all the way down and hold in position. Specification: 65-69% (accelerator pedal pressed down)
3. Press accelerator all the way down (past Kick-Down point) Specification: 70-74% (accelerator pedal pressed down past kick-down point)

If the specification is not obtained

Scheme 116

1. Remove knee protection bar on driver's side. See «KNEE BAR AND BRACKET, DRIVER SIDE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-equipment__knee-bar-and-bracket-driver-side).
2. Remove left front floor mat.
3. Unscrew nut -3-. see scheme 134
4. Unscrew Allen bolt -2-.
5. Remove A-pillar trim bottom left -1-.
6. Remove left air channel below instrument cluster.
7. Check installation position of cable cam, and adjust if necessary. See «ACCELERATOR PEDAL POSITION SENSOR, ADJUSTING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays).

If installation position is OK.

Scheme 117

1. Adjust operating rod of cable cam as follows
2. Disconnect operating rod -1- from accelerator pedal -2- -arrow-.
3. Turn threaded piece of operating rod to adjust.
4. Afterwards, reconnect operating rod carefully.
5. Check adjustment, see above.
6. Install air channel, lower A-pillar trim and floor mat.
7. Install knee protection bar. See «KNEE BAR AND BRACKET, DRIVER SIDE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-equipment__knee-bar-and-bracket-driver-side) .

Scheme 118

Scheme 119

1. VAG1526A multimeter
2. VAG1594 A connector test kit

Test sequence

Note. Check kick-down switch function in read measuring value block function 08.

See ON BOARD DIAGNOSTIC (OBD) - 5 SPD. AUTOMATIC TRANSMISSION (01L, AWD) , READ MEASURING VALUE BLOCK (FUNCTION 08) .

Scheme 120

Scheme 121

1. Remove left front floor matt.
2. Unscrew cover for kick-down switch -arrow-.
3. Disconnect 2-pin harness connector from kick-down switch -F8 (item -12-, see «ACCELERATOR PEDAL LINKAGE (VEHICLES WITH ELECTRONIC THROTTLE CONTROL), SERVICING»(/audi/a8/d3-2002-2005/remont/fuel-system/#fuel-supply-system-42l-v8-akb-aux-ays__accelerator-pedal-linkage-vehicles-with-electronic) ).
4. Carefully lift safety latch -arrow- and turn stop counter clockwise.
5. Remove kick-down switch.
6. Connect multimeter to kick-down switch (resistance range) Specification: infinity Ohm (no continuity)
7. Press Kick-Down switch Shortly after kick-down point, reading must drop to 0 Ohm.

See also:
• FUEL PUMP (FP) RELAY -J17- AND RELAY ACTIVATION, CHECKING
• PARKING BRAKE CABLES
• SUSPENSION - REAR
• FUEL PRESSURE REGULATOR AND RESIDUAL FUEL PRESSURE, CHECKING
• SIGNAL FROM SENDER FOR FUEL GAUGE -G-, CHECKING
• REAR WHEELHOUSING LINER, REMOVING AND INSTALLING
• MOTRONIC ENGINE CONTROL MODULE (ECM) -J220- (WITHOUT METAL ANTI -THEFT HOUSING), REPLACING
• WHEELHOUSING LINER
• ON BOARD DIAGNOSTIC (OBD) - 5 SPD. AUTOMATIC TRANSMISSION (01L, AWD)
• KNEE BAR AND BRACKET, DRIVER SIDE, REMOVING AND INSTALLING
• READ MEASURING VALUE BLOCK (FUNCTION 08)
• FUEL SUPPLY SYSTEM
• SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY SYSTEM
• RULES FOR CLEANLINESS
• FUEL TANK, DRAINING
• FUEL FILLER NECK WITH EXPANSION TANK, COMPONENT OVERVIEW
• POSITION OF CROSS BRACE
• POSITION OF DOUBLE HOSE CLAMP
• FUEL TANK WITH ATTACHMENTS, REMOVING AND INSTALLING
• FUEL LEVEL SENSORS, REMOVING AND INSTALLING
• REMOVING AND INSTALLING FUEL LEVEL SENSOR 2 -G169- (LEFT)
• FUEL DELIVERY MODULE, REMOVING AND INSTALLING
• FUEL PUMP, ELECTRICAL TESTING
• CHECKING CURRENT DRAW
• CHECKING VOLTAGE SUPPLY
• LEAK CHECKING
• FUEL DELIVERY MODULE AND FUEL LEVEL SENDERS, REMOVING AND INSTALLING
• INSTALLATION POSITION OF GROUND (GND) CONNECTION
• BLEED VALVE, REMOVING AND INSTALLING
• GRAVITY VALVE, CHECKING
• EVAP CANISTER, REMOVING AND INSTALLING
• EVAP SYSTEM, AUTOMATIC LEAK TESTING
• EVAP SYSTEM, LEAK TESTING USING VAS5051 OR VAG1551
• CHECKING FUEL SUPPLY AND TANK VENTILATION SYSTEM FOR LEAKS
• CHECKING INTERNAL RESISTANCE
• EVAP SYSTEM LEAK DETECTION SYSTEM, FUNCTION
• ACCELERATOR PEDAL LINKAGE (VEHICLES WITH ELECTRONIC THROTTLE CONTROL), SERVICING