WM Audi A8 Fuel supply system, diesel engines [82s].pdf

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Service
Workshop Manual
Audi A8 1994 ➤
Engine ID
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or in whole, is not
Fuel supply system,
authorised by AUDI AG. AUDI AG does not guaranteepart accept any liability
diesel engines
permitted unless
or
AFB
with respect to the
AKE AKF
correctness of information in this document. Copyright by AUDI AG.
AKN
Edition 12.2007
Service Department. Technical Information
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
20 - Fuel supply system
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt
A0050808820
Audi A8 1994 ➤
Fuel supply system, diesel engines - Edition 12.2007
Contents
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
4
4.1
4.2
4.3
4.4
4.5
5
5.1
5.2
5.3
5.4
General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank with attached components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining fuel tank with intact fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining fuel tank with defective fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . .
Fuel expansion chamber - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel delivery unit and fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel delivery unit and fuel gauge senders - exploded view . . . . . . . . . . . . . . . . . . . . . . . .
Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel pump relay J17 and activation - vehicles with 6-cylinder engine . . . . . . . . . .
Checking fuel pump relay J17 and activation - vehicles with 8-cylinder engine . . . . . . . . . .
Checking fuel system pressurisation pump G6 (electrical test) - vehicles with 6-cylinder or 8-
cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel delivery unit - vehicles with 6-cylinder and 8-cylinder engine
........................................................................
Checking fuel delivery unit for leaks - vehicles with 6-cylinder and 8-cylinder engines . . . .
Checking electric fuel pump 2 relay J49 and activation - vehicles with 8-cylinder engine . .
Checking fuel pump G23 (electrical test) - vehicles with 8-cylinder engine . . . . . . . . . . . .
Removing and installing fuel pump G23 - vehicles with 8-cylinder engine . . . . . . . . . . . . . .
Checking fuel cooling pump relay J445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel cooling pump V166 - vehicles with 8-cylinder engine . . . . . .
Checking fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel gauge sender 2 G169 (left-side) . . . . . . . . . . . . . . . . . . . . . .
Checking low fuel level sender G210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
3
3
4
5
6
12
14
14
16
17
23
29
32
40
41
46
49
50
50
51
54
56
58
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fuel filter - exploded view . . . . . .
Protected by
.
copyright. CopyingAUDI
. . .
AUDI
.
AG
.
does
.
not
.
guarantee or
.
or
.
in whole,liability
. . . . . . . . . . . . . . . .
for private or
. . . .
purposes, in part accept any is
61
. .
AG.
.
commercial
. . . . . . . . . . .
not
permitted unless authorised by
Removing and installing fuel filter . .
with
.
respect to
. .
correctness
.
of
.
information
.
in this document.
.
Copyright by
.
AUDI
.
AG.
62
. . . . . .
the
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Checking fuel system for leaks - vehicles with 6-cylinder engine . . . . . . . . . . . . . . . . . . . . 63
Checking fuel system for leaks - vehicles with 8-cylinder engine . . . . . . . . . . . . . . . . . . . . 65
Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Accelerator mechanism on left-hand drive vehicles - exploded view . . . . . . . . . . . . . . . . . . 67
Accelerator mechanism on right-hand drive vehicles - exploded view . . . . . . . . . . . . . . . . 69
Checking accelerator position sender G79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Adjusting accelerator position sender G79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Contents
i
Audi A8 1994 ➤
Fuel supply system, diesel engines - Edition 12.2007
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
ii
Contents
Audi A8 1994 ➤
Fuel supply system, diesel engines - Edition 12.2007
20 –
1
1.1
Fuel supply system
General repair instructions
Safety precautions
When removing and installing components from a full or partly full
fuel tank, note the following:
♦ Fuel tank must not be full. The amount of fuel which can be
left in the tank is indicated in the corresponding procedure de‐
scription. Drain the tank if necessary. Procedure with intact
fuel delivery unit
⇒ page 4
; procedure with defective fuel
delivery unit
⇒ page 5
.
♦ Before commencing work, switch on exhaust extraction sys‐
tem and place an extraction hose close to the sender opening
in the fuel tank to extract escaping petrol fumes. If no exhaust
extraction system is available, a radial fan with a displacement
of at least 15 m
3
/h can be used (the fan motor must be clear
of the air stream).
♦ Avoid skin contact with fuel. Wear fuel-resistant gloves.
When removing and installing the fuel tank, note the following:
♦ Fuel tank must be empty to reduce weight. Drain the tank if
necessary. Procedure with intact fuel delivery unit
⇒ page 4
; procedure with defective fuel delivery unit
⇒ page 5
.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Even small
the correctness
of
information in this document. Copyright by AUDI AG.
work‐
with respect to
amounts
of
dirt can cause malfunctions. When
1.2
Rules for cleanliness
ing on the fuel supply system and injection system, pay careful
attention to the following basic rules:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Seal off open lines and connections with clean plugs or sealing
caps immediately.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
♦ Please ensure that no diesel fuel contacts coolant hoses.
Should this occur, the coolant hoses must be cleaned imme‐
diately. Renew coolant hoses if damaged.
1.3
•
Test conditions
Battery voltage at least 12.5 V
1. General repair instructions
1

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