1.9-I fuel from the fuel tank is taken by the high pressure fuel pump and only the fuel intake is located in the tank. On all-wheel drive vehicles with diesel engines 1.9-I 115/130 hp. The fuel pump is installed in the fuel tank.
Structurally, it consists of a potentiometer and a float associated with it. When the fuel in the tank decreases, the sensor float drops and, by increasing the resistance of the potentiometer, lowers the voltage on the fuel gauge located in the instrument cluster.
Note: All-wheel drive vehicles have three fuel level sensors. This is due to the fact that the fuel tank has a complex, stepped design. The fuel level sensor also contains a fuel pump located on the right under the rear seat.
Safety instructions. When removing the fuel pump, a small amount of fuel may spill. Fuel fumes are poisonous and flammable, so keep your work area well ventilated. Avoid skin contact with fuel. Use fuel resistant gloves. Do not use open flame - fire hazard! Make sure there is a charged fire extinguisher in the immediate vicinity of the workplace.
Use the maximum fuel from the tank before removing the fuel tank. To ventilate the workplace, you can use a radial fan, the electric motor of which is located outside the air flow.
Withdrawal
Turn off the ignition and remove the wire «masses» with battery.
Attention
- When the wires are disconnected from the battery terminals, the data on the recorded malfunctions are erased in the memory blocks of the control devices, therefore, before disconnecting the wires, it is necessary to contact the workshop to recall the malfunctions recorded in it. After connecting the wires to the battery terminals, it is necessary to activate and reprogram the power windows, as well as the position of the rear-view mirrors and seats.
- If the car has a radio with a code, then before disconnecting the wires from the terminals from the battery, check that there is a code to reactivate the receiver. Otherwise, it will be possible to put the radio receiver into operation only at a specialized station.
Front wheel drive vehicles.Remove the carpet in the trunk and unscrew and remove the fuel gauge/fuel pump access cover.
All wheel drive vehicles. Remove the rear seat to access the fuel pump/fuel gauge.
Disconnect the connector from the fuel level sensor / fuel pump (see fig. 4A.3).
Safety instructions. The fuel supply line is under pressure. Depressurize the fuel system before disconnecting the fuel line. To do this, loosen the fuel line clamp, then cover the connection with a rag and, being careful, remove the fuel hose from the fitting. Wear safety goggles to protect your eyes from fuel.
Loosen the clamps and remove the supply and return fuel lines from the fittings of the mounting flange (see fig. 4A.3). Seal the ends of the fuel lines with suitable plugs.
Using the AUDI-3217 special tool, unscrew the flange nut (see fig. 4A.4). To unscrew the flange nut on four-wheel drive vehicles, you must use the special tool AUDI-3087. If no such tool is available, unscrew the flange nut using a block of wood and a hammer.
Remove the mounting flange and sealing ring from the fuel tank opening.
From the underside of the mounting flange, mark and disconnect the electrical connectors and fuel hoses.
All wheel drive vehicles.Hold the fuel line to the second fuel level sensor.
From the underside of the flange, support the fuel lines, mark and disconnect the electrical connectors.
Vehicles with petrol engines. Remove the fuel level sensor while pressing the latch on the housing (see fig. 4A.5).
Vehicles with petrol engines. Using the special tool AUDI-3307, release the fuel pump from the retainer by turning it 15°and remove the fuel pump from the tank (see fig. 4A.6). Fixation of a special tool is carried out in the slots of the fuel pump housing.
Drain the fuel from the fuel pump into a suitable container.
Vehicles with diesel engines. Unclip the fuel level sensor and remove it from the fuel tank.
Installation
Dip the fuel pump/fuel gauge O-ring into fuel before installing.
Vehicles with petrol engines. Install the fuel pump so that mark 1 (pic. 4A.7) on the pump is aligned with mark 2 on the housing.
Using the AUDI-3307 special tool, turn the fuel pump clockwise until it stops, with mark 1 (pic. 4A.7) must align with mark 3 on the case.
Attach the fuel level sensor to the brackets.
From the underside of the flange, connect, in accordance with the previously marked marks, the fuel lines and electrical connectors. Secure the fuel lines with new clamps.
Vehicles with petrol engines. Install the mounting flange so that the mark on the flange is aligned with the mark on the fuel tank (see fig. 4A.8).
Attention. On vehicles with diesel engines, the arrow on the flange must be aligned with the mark «TDI» on the fuel tank.
Screw on the flange nut and, using the special tool AUDI-3217, tighten it to a torque of 80 Nm. If no such tool is available, screw in the flange nut using a block of wood and a hammer.
Put the supply and return fuel hoses on the fitting of the mounting flange and secure them with new clamps. The arrows on the fittings indicate the direction of fuel flow. The fuel return hose is blue.
Connect the electrical connector to the mounting flange.
Place the cover over the mounting flange and screw it on.
Upon completion of assembly, check that the fuel and vent pipes are properly attached to the fuel tank.
Place a floor mat in the trunk. In all-wheel drive vehicles, install the rear seat.
Connect wire «masses» to the battery. Repeat the operations for memorizing the position of seats, mirrors, etc., as well as set the time on the clock and enter the code into the radio.
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