Fuel Supply System - All Engines

• Fuel supply system components, removing and installing
  • General repair notes
  • Safety precautions
  • Rules of cleanliness
• Fuel supply, Front Wheel Drive (FWD)
  • Notes
  • Fuel tank with sub components, component overview
    • Notes
    • Checking procedure of Ground (GND) connection
    • Vent valve removing, installing and checking
      • Removing
      • Checking
  • Fuel tank, draining
    • Notes
    • Special tools and required equipment
    • Work sequence
      • Notes
      • A - Procedure on fuel tank that contains more than 3/4fuel
      • B - Procedure on fuel tank that contains less than 3/4fuel
  • Fuel tank with attachments, removing and installing
    • Special tools and required equipment
    • Removing
    • Vehicles with level control system
    • Installing
    • Tightening torques
  • Fuel pump module including sender for fuel gauge, component overview
    • Notes
    • Harness connector unlocking
  • Fuel pump, checking electrically
    • Special tools, test equipment and auxiliary items
    • Test requirements
    • Test sequence
  • Fuel pump delivery rate, checking
    • Special tools, testers and auxiliary items
    • Requirements for test:
    • Test sequence
  • Fuel pump module, removing and installing
    • Special tools and test equipment
    • Removing
    • Installing
    • Tightening torque
  • Sender for fuel gauge-G-, checking - front wheel drive (FWD)
    • Special tools and equipment
    • Checking procedure
  • Sender for fuel gauge-G, removing and installing
    • Removing
    • Installing
• Fuel supply, All Wheel Drive (AWD)
  • Notes
  • Fuel tank with attachments, component overview - vehicles with 6-cylinder engine and A6 Allroad
    • Notes
    • Installation position of Ground wire
  • Fuel tank, draining
    • Notes
    • Special tools and required equipment
    • Work sequence
      • Notes
      • A - Procedure on fuel tank more than 1/4 full
      • B - Procedure on fuel tank less than 1/4 full
  • Fuel tank with attachments, removing and installing - vehicles with 6-cylinder engine and A6 Allroad
    • Special tools, testers and auxiliary items
    • Removing
    • Installing
    • Tightening torque
  • Fuel filler neck with expansion tank, component overview - vehicles with 6-cylinder engine and A6 Allroad
    • Notes
    • Installation position of Ground wire
  • Fuel filler neck with expansion tank, removing and installing - vehicles with 6-cylinder engine and A6 Allroad
    • Removing
    • Installing
    • Tightening torque
  • Fuel tank with attachments, component overview - vehicles with 8-cylinder engine except A6 Allroad
    • Notes
    • Installation position of Ground wire
  • Fuel tank with attachments, removing and installing - vehicles with 8-cylinder engine except A6 allroad
    • Notes
    • Special tools, testers and auxiliary items
    • Removing
    • Installing
    • Tightening torque
  • Fuel filler neck with expansion tank, component overview - vehicles with 8-cylinder engine except A6 Allroad
    • Notes
    • Installation position of Ground wire
  • Fuel filler neck with expansion tank, removing and installing - vehicles with 8-cylinder engine except A6 Allroad
    • Removing
    • Installing
    • Tightening torque
  • Seal insert for gas station fuel nozzle, removing and installing - all engines
    • Special tools and test equipment
    • Removing
    • Installing
  • Fuel pump module with sender for fuel gauge, component overview - all engines
    • Notes
    • Part I
    • Component overview fuel sender with fuel pump -G6- all engines
      • Notes
      • Release harness connector
      • Unblocking return pipe
  • Fuel pump, checking electrically
    • Special tools, test equipment and auxiliary items
    • Test requirements
    • Test procedure
  • Fuel pump delivery volume, checking - vehicles with 6-cylinder naturally aspirated engine
    • Test requirements
    • Test sequence
  • Fuel pump delivery volume, checking - vehicles with 6-cylinder turbo engine
    • Test requirements
    • Test sequence
  • Fuel pump delivery volume, checking - vehicles with 8-cylinder engine (with toothed belts)
    • Test requirements
    • Test sequence
  • Fuel pump delivery volume, checking - vehicles with 8-cylinder engine (open loop system)
    • Test requirements
    • Test sequence
  • Fuel sender with fuel pump, removing and installing
    • Special tools, test equipment and auxiliary items
    • Removing
    • Installing
    • Tightening torque
• Fuel transfer system - Vehicles with 8 - cylinder engine
  • Function
  • Component overview, Transfer Fuel Pump (FP) -G23-
  • Fuel Pump (FP) -G6-, checking
    • Special tools, testers and auxiliary items
    • Test conditions:
    • Test sequence
  • Transfer Fuel Pump (FP) -G23-, checking
    • Special tools, testers and auxiliary items
    • Test conditions:
    • Test sequence:
  • Fuel Pump (FP) Control Module -J538-, checking
    • Special tools, testers and auxiliary items
    • Test conditions:
    • Test sequence
    • Voltage supply, checking
    • Activation by ECM, checking
    • Diagnosis circuit, checking
    • Voltage supply for Fuel Pump (FP) -G6- (of the Fuel Pump (FP) Control Module -J538-), checking
    • Voltage supply for fuel pump -G23 (from fuel pump control module -J538), checking
    • Tightening torque
  • Fuel pump delivery rate, checking
    • Special tools, testers and auxiliary items
    • Requirements for test:
    • Test sequence
  • Fuel pump (FP) -G6-, removing and installing
  • Transfer fuel pump (FP) -G23-, removing and installing
    • Special tools, testers and auxiliary items
    • Removing
    • Installing
    • Tightening torque
• Sender for Fuel gauge - All Wheel drive
  • Sender for fuel gauge, checking
    • Special tools, testers and auxiliary items
    • Test sequence
    • Vehicles with build date up to approx. 02/99
    • Vehicles with build date as of approx 02/99
  • Sender for fuel gauge -G-, removing and installing
    • Notes
    • Removing
    • Installing
  • Fuel Level Sensor 2 -G169-, removing and installing
    • Notes
    • Special tools, test equipment and auxiliary items
    • Removing
    • Installing
    • Tightening torque
  • Fuel Supply Sensor 3 -G237-, removing and installing
    • Notes
    • Special tools, test equipment and auxiliary items
    • Removing
      • Notes
      • Audi A6:
      • Audi RS6:
      • All:
      • Limosine:
      • Avant:
    • Installing
    • Tightening torque
• Suction jet pump-all wheel drive (AWD)
  • Function
  • Suction jet pump with distributor connector, checking - vehicles with 6-cylinder naturally aspirated engine
    • Special tools, test equipment and auxiliary items
    • Requirements for test:
    • Test sequence
  • Suction jet pump with distributor connector, checking - vehicles with 6-cylinder turbo engine
    • Special tools, test equipment and auxiliary items
    • Requirements for test:
    • Test sequence
  • Suction jet pump with distributor connector, checking - vehicles with 8-cylinder engine (with toothed belts)
    • Special tools, test equipment and auxiliary items
    • Requirements for test:
    • Test sequence
  • Suction jet pump with manifold test -vehicles with 8-Cylinder-naturally aspirated engine (with open-loop system)
    • Special tools, testers and auxiliary items
    • Test conditions:
    • Test sequence
  • Suction jet pump with manifold test - vehicles with 8-cylinder-Turbo engine
    • Special tools, testers and auxiliary items
    • Test conditions:
    • Test sequence
  • Suction jet pump with distributor connector, removing and installing
    • Special tools, test equipment and auxiliary items
    • Removing
    • Installing
    • Tightening torque
• Fuel filter - component overview
  • Notes
  • Fuel filter -component overview, vehicles with 8-Cylinder-Turbo engine
  • Fuel filters for vehicles with 8-Cylinder-Turbo engine, removal and installation
    • Special tools, testers and auxiliary items
    • Removing
    • Installing
    • Tightening torque
• EVAP canister/tank leak diagnostic system, servicing - FWD & AWD
  • Notes
  • Emission Evaporative (EVAP) canister, removing and installing
    • Notes
    • Removing
    • Installing
    • Tightening torque
  • EVAP canister/tank leak diagnostic system, diagram - 6-cylinder naturally aspirated engine
  • EVAP canister/tank leak diagnostic system, diagram - 6-cylinder turbo engine
  • EVAP canister/tank leak diagnostic system, diagram - 8-cylinder naturally aspirated engine
  • EVAP canister/tank leak diagnostic system, diagram - 8-cylinder Turbo engine
  • Fuel tank, leak diagnostic system
    • Function
  • Automatic Evaporative Emission (EVAP) system, diagnostic leak test
  • Diagnostic leak test, performing
    • Notes
    • Special tools, testers and auxiliary items
    • Test requirements
    • Test procedure
    • Error display
  • Evaporative Emissions (EVAP) System Diagnosis using KLI9210 EVAP Tester
    • Description
    • Test EVAP system using Leak Detection Pump (LDP) -V144- (m.y. 1998 and later)
    • Perform EVAP tester self-test
    • Calibrate KLI9210 Tester
    • Test fuel cap
    • Test LDP -V144- for internal leaks
    • Test EVAP System
    • Method 1: Locate leak with smoke generator
    • Method 2: Locate leak with ultrasonic tester
  • Tank leak diagnostic, performing
    • Notes
    • Special tools and test equipment
    • Checking fuel supply and tank ventilation system for leaks
  • Leak Detection Pump (LDP) -V144-, checking
    • Special tools and equipment
    • Test sequence:
    • Test procedure
    • Internal resistance test
    • Voltage supply test
    • Output circuit checking - Vehicles with mechanical accelerator operation
    • Input circuit checking - Vehicles with mechanical accelerator operation
    • Output circuit checking - Vehicles with electronic engine power control (drive-by wire)
    • Input circuit checking - Vehicles with electronic engine power control (drive-by wire)
  • Leak Detection Pump (LDP) -V144-, removing and installing
    • Removing
    • Installing
    • Tightening torque
• Accelerator Pedal (AP) cable, servicing - vehicles with mechanical accelerator mechanism
  • Accelerator pedal cable, removing and installing
    • Notes
    • Removing
      • Notes
      • Vehicles with automatic transmission
      • All:
    • Installing
      • Notes
      • Vehicles with manual transmission
      • Vehicles with automatic transmission
      • All:
  • Accelerator pedal cable, adjusting
    • Notes
    • Vehicles with manual transmission
    • Vehicles with automatic transmission
    • All vehicles
  • Accelerator pedal cable, checking - vehicles with automatic transmission (kick-down switch, checking)
    • Special tools and equipment
    • Test sequence
• Accelerator Pedal (AP), servicing - vehicles with Electronic Power Control (EPC) (drive by wire)
  • Notes
  • Accelerator Pedal (AP) with position sensors, removing and installing
    • Removing:
    • Installing:
    • Tightening torque