Fuel Supply System: Overview Audi S8 D3 facelift

In-tank wire routing, assembly overview

Note. The illustration shows the ideal routing of the lines on the inside of the fuel tank. With exception of the line position --> Installed location of fuel delivery lines , exact routing of the lines is not required, although you must be generally aware of clearance between components and of preventing rattling noises. - Arrow - points in direction of travel.

Scheme 1

1 - Left fuel delivery unit with Transfer Fuel Pump (FP) G6

2 - Fuel delivery line

1. From left suction jet pump to right fuel delivery unit

3 - Suction jet pipe

1. From right fuel pump to left suction jet pump

4 - Left suction jet pump

5 - Expansion tank

1. With suction jet pump to pump fuel from reservoir

6 - Check valve

1. For fuel filler line

7 - First-time filling fuel line

1. To right fuel delivery unit
2. Serves to supply a small amount of fuel directly to delivery unit during first-time filling

8 - Right suction jet pump

9 - Suction jet pipe

1. From right fuel pump to right suction jet pump

10 - Fuel delivery line

1. From right suction jet pump to left fuel delivery unit

11 - Right fuel delivery unit with Fuel Pump (FP) G23

12 - Vent line

1. To vent connection at top on fuel filler neck

13 - Fuel supply line

1. From left and right fuel pumps to locking flange

14 - Vent line

1. To evaporative emissions (EVAP) canister in spare wheel well on vehicle floor

15 - Fuel filling line

1. From filler tube to check valve in fuel tank

16 - Fuel return line

1. From locking flange to left and right fuel delivery units

17 - Suction jet pipe

1. To suction jet pump in reservoir

Scheme 2

1. The delivery lines - 1 - and - 3 - must be routed under \ fuel filler line - 2 - in \ area of \ left fuel tank opening.

Scheme 3

1 - Support

1. For fuel delivery unit

2 - Fuel Level Sensor G

1. Black
2. Clipped into mount - 1
3. Resistance values, checking --> «Fuel Level Sensor G , checking (left lever-type sensor)»(ref-289201-S15195528772008062700000)
4. Removing and installing --> «Fuel Level Sensor G (left lever-type sensor), removing and installing»(ref-289201-S35646376482008062700000)

3 - Left fuel delivery unit

1. With Transfer Fuel Pump (FP) G6
2. Clipped into mount - 1
3. Different versions
4. Fuel pump electrical, checking --> «Transfer Fuel Pump (FP) G6 (left), checking electrical»(ref-289201-S01810420482008062700000)

1. Checking residual pressure --> «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289205-S08445194072008062700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BVJ 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): BFM «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289209-S01888638322008062700000) for 5.2 LITER 10-CYL. 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BSM «24 FUEL INJECTION SYSTEM»(ref-289212-S05463344962008062700000) for 6.0 LITER 12-CYL. 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BSB
2. Removing and installing --> «Left fuel delivery unit with Transfer Fuel Pump (FP) G6 , removing and installing»(ref-289201-S15723393932008062700000)
3. After installing, fuel vehicle with at least 5 liters of fuel

4 - Fuel delivery line

1. From suction jet pump, right side
2. Clipped onto fuel delivery unit - 3

5 - Fuel supply line

1. The connection is located on right side of fuel tank
2. To disconnect, press release button on connection piece

6 - Fuel return line

1. The connection is located on right side of fuel tank
2. To disconnect, press release button on connection piece

7 - Locking ring

1. Use wrench T10202 for removal and installation
2. Tighten to 120 Nm

8 - Left locking flange

1. Installed location --> «Installed location of left locking flange»(ref-289201-S09243504002008071700000)

9 - Seal

1. Replace
2. Install dry

10 - Fuel Level Sensor 3 G237

1. Gray
2. Clipped onto fuel delivery unit - 3
3. Resistance values, checking --> «Fuel Level Sensor 3 G237 , checking (left tubular sensor)»(ref-289201-S42807097702008062700000)
4. Removing and installing --> «Fuel Level Sensor 3 G237 (left tubular sensor), removing and installing»(ref-289201-S42064210972008062700000)

Scheme 4

1. Install new locking flange seal dry.
2. Insert locking flange in fuel tank, note installation position

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

Scheme 5

Special tools, testers and auxiliary items required

1. Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2
2. Portable multimeter V.A.G 1526C
3. Connector test set V.A.G 1594C
4. Vehicle Diagnosis, Testing and Information System VAS 5051 with inductive pickup (50 A) VAS 5051/9

Work procedure

Vehicles of model year 2003

Scheme 6

1. Fuse 10 on fuse panel SF10 (in relay and fuse panel in right of luggage compartment) O.K.

Vehicles as of model year 2004

Scheme 7

1. Fuse 2 on fuse panel SF2 (in relay and fuse panel in right of luggage compartment) O.K.

All

1. Fuel Pump (FP) 2 Relay J49 O.K. (on relay and fuse panel in right of luggage compartment, Socket 3).
2. Battery voltage min. 12.5 V
3. Fuel filter OK.
4. Ignition switched off.

Accelerator pedal mechanism, assembly overview

Note. On vehicles with automatic transmissions, a separate Kick Down Switch F8 is installed. Kick down switch F8 , removing and installing --> Kick down switch F8 , removing and installing .

Scheme 8

1 - Accelerator pedal module

1. With Throttle Position (TP) Sensor G79 and Accelerator Pedal Position Sensor 2 G185
2. Removing and installing --> «Accelerator pedal module with Throttle Position (TP) sensors, removing and installing»(ref-289201-S01156152812008062700000)

2 - 10 Nm

3 - Electrical harness connector

4 - 10 Nm