Service

Workshop Manual
Audi A8 2003 ➤
Fuel supply system, diesel engines
Engine ID ASB ASE BNG BVN BMC

Edition 12.2013

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.

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
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 © 2014 Audi AG, Ingolstadt A0051006320

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Fuel tank with components - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Routing of pipes/hoses (inside fuel tank) - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Fuel delivery unit (left-side) with fuel system pressurisation pump G6 ; fuel gauge sender G
and fuel gauge sender 3 G237 - exploded view of components . . . . . . . . . . . . . . . . . . . . 17
1.6 Removing and installing fuel delivery unit (left-side) with fuel system pressurisation pump G6
...................................................................... 18
1.7 Fuel delivery unit (right-side) with fuel pump G23 ; fuel gauge sender 2 G169 and fuel gauge
sender 4 G393 - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.8 Removing and installing fuel delivery unit (right-side) with fuel pump G23 . . . . . . . . . . . . 29
1.9 Checking fuel pump delivery rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.10 Suction-jet pumps: operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.11 Removing and installing suction-jet pump (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.12 Removing and installing suction-jet pump (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Checking fuel gauge sender G (lever-type sender, left-side) . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Removing and installing fuel gauge sender G (lever-type sender, left-side) . . . . . . . . . . . . 46
2.3 Checking fuel gauge sender 2 G169 (lever-type sender, right-side) . . . . . . . . . . . . . . . . . . 47
2.4 Removing and installing fuel gauge sender 2 G169 (lever-type sender, right-side) . . . . . . 48
2.5 Checking fuel gauge sender 3 G237 (tubular sender, left-side) . . . . . . . . . . . . . . . . . . . . . . 49
2.6 Removing and installing fuel gauge sender 3 G237 (tubular sender, left-side) . . . . . . . . . . 50
2.7 Checking fuel gauge sender 4 G393 (tubular sender, right-side) . . . . . . . . . . . . . . . . . . . . 54
2.8 Removing and installing fuel gauge sender 4 G393 (tubular sender, right-side) . . . . . . . . 56
3 Fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Removing and installing fuel cooler on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Removing and installing fuel cooler on engine - vehicles with 8-cylinder 4.0 ltr. TDI engine
........................................................................ 64
4 Servicing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.1 Fuel filter - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1 Checking fuel system for leaks (vehicles with 6-cyl. TDI engine) . . . . . . . . . . . . . . . . . . . . 69
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6.2 Checking fuel system
permitted unlessfor leaksby(vehicles
authorised AUDI AG. AUDI with 8-cyl.
AG does 4.0 ltr. TDI
not guarantee engine)
or accept any liability. . . . . . . . . . . . . . 70
6.3 Checking fuelwith system
respect tofor
the leaks (vehicles
correctness with
of information 8-cyl.
in this 4.2Copyright
document. ltr. TDIbyengine)
AUDI AG. .............. 72
7 Servicing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.1 Accelerator mechanism - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.2 Removing and installing accelerator pedal module with accelerator position sender . . . . 76
7.3 Checking kickdown switch F8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.4 Removing and installing kickdown switch F8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Contents i
 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

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 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

00 – Technical data
1 Safety precautions
(ARL003638; Edition 12.2013)
⇒ “1.1 Safety precautions when working on the fuel system”, page
1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2

1.1 Safetyby AUDI precautions

AG. AUDI AG doeswhen working on the
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised not guarantee or accept any liability

fuel system
with respect to the correctness of information in this document. Copyright by AUDI AG.

When working on the fuel system note the following warnings:

WARNING

Risk of injury - fuel system operates under pressure.

♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.
♦ Wear protective gloves.
♦ Wear safety goggles.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Health risk: avoid skin contact with fuel.
♦ Avoid skin contact with fuel. Wear fuel-resistant gloves.

Perform the following steps before starting work on the fuel sys‐
tem:
♦ Fuel tank must not be full. The amount of fuel which can be
left in the fuel tank is indicated in the corresponding procedure
description. Drain fuel tank if necessary ⇒ page 7 .
♦ Before commencing work, switch on exhaust extraction sys‐
tem and place an extraction hose close to the 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 m3/h can be used (the fan motor
must be clear of the air stream).

WARNING

Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when installing and removing to
reduce weight. Drain fuel tank if necessary ⇒ page 7 .

1. Safety precautions 1
 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Observe the following points to prevent personal injuries and

damage to the injection and glow plug system:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as
injectors and gas-discharge headlights.
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
♦ When installing, note colour coding of plug-in connectors.
♦ Plug-in connectors should engage audibly when connecting.
♦ Pull plug-in connectors to check that they are correctly engag‐
ed.
♦ Erase any entries in event memory resulting from testing or
installation ⇒ Vehicle diagnostic tester, Guided Functions ,
then Interrogate event memory .

Caution

To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery
Protected ⇒ Electrical
by copyright. system;
Copying for Rep. gr.purposes,
private or commercial 27 . 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.

1.2 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:

WARNING

Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.

2 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

2 Repair instructions
⇒ “2.1 Rules for cleanliness”, page 3
⇒ “2.2 Test conditions”, page 3
⇒ “2.3 Contact corrosion”, page 3
⇒ “2.4 Routing and attachment of pipes, hoses and wiring”, page
4

2.1 Rules for cleanliness

Even small amounts of dirt can cause malfunctions. When work‐
ing on the fuel supply system and injection system, pay careful
attention to the following basic rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ 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 not been stored in their packing (e.g. in tool boxes
etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
♦ Make sure that no diesel fuel comes into contact with other
components in the engine compartment. If necessary, clean
immediately.

2.2 Test conditions

• Battery in standby mode ("Stützbetrieb") ⇒ Electrical system;
Rep. gr. 27 .
• Fuses for fuel pump/ fuel pump relay - J17- / fuel pump control
unit - J538- OK ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations. 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
• Fuel pump relay - J17- OK ⇒with Current flow
respect to diagrams,
the correctness Electrical
of information in this document. Copyright by AUDI AG.
fault finding and Fitting locations.
• Fuel pump control unit - J538- OK; checking in Guided Fault
Finding ⇒ Vehicle diagnostic tester.

• Fuel tank at least 1/4 full.

• Fuel filter OK.
• Fuel lines OK (not obstructed or crushed).
• Ignition off.

2.3 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).

2. Repair instructions 3
 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.

2.4 Routing and attachment of pipes, hoses

and wiring

Caution

Risk of damage to pipes/hoses/wiring.

♦ The original routing must be restored when installing any
kind of pipes/hoses/wiring.
♦ Due to the restricted space in the engine compartment, it
is important to ensure sufficient clearance from all moving
or hot components.

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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.

4 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

20 – Fuel supply system

1 Fuel supply system
⇒ “1.1 Fuel tank with components - exploded view”, page 5
⇒ “1.2 Draining fuel tank”, page 7
⇒ “1.3 Removing and installing fuel tank with attached compo‐
nents”, page 10
⇒ “1.4 Routing of pipes/hoses (inside fuel tank) - overview”, page
16
⇒ “1.5 Fuel delivery unit (left-side) with fuel system pressurisation
pump G6 ; fuel gauge sender G and fuel gauge sender 3 G237 -
exploded view of components”, page 17
⇒ “1.6 Removing and installing fuel delivery unit (left-side) with
fuel system pressurisation pump G6 ”, page 18
⇒ “1.7 Fuel delivery unit (right-side) with fuel pump G23 ; fuel
gauge sender 2 G169 and fuel gauge sender 4 G393 - exploded
view of components”, page 27
⇒ “1.8 Removing and installing fuel delivery unit (right-side) with
fuel pump G23 ”, page 29
⇒ “1.9 Checking fuel pump delivery rate”, page 38
⇒ “1.10 Suction-jet pumps: operation”, page 40
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⇒ “1.11 Removing and installing suction-jet pump (left-side)”,
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

page 41
with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ “1.12 Removing and installing suction-jet pump (right-side)”,

page 43

1.1 Fuel tank with components - exploded view

1. Fuel supply system 5

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

1 - Securing strap
❑ With spacer, installation
position ⇒ page 7
2 - 22 Nm
3 - Fuel supply line
❑ To fuel filter
❑ Mark before removing
❑ Clip onto fuel tank
4 - Fuel return line
❑ From fuel cooler
❑ Mark before removing
❑ Clip onto fuel tank
5 - Supply line
❑ To auxiliary heater
6 - Earth connection
❑ To eliminate electrostat‐
ic charge
❑ Installation position /
test procedure
⇒ page 7
❑ Make sure that connec‐
tor is securely fitted
❑ After installation, use anCopying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
ohmmeter to check
permitted unless the
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
electrical connection
with respect to the correctness of information in this document. Copyright by AUDI AG.
between the fuel filler
neck and a bare metal
part on the body. Speci‐
fication: approx. 0 Ω
7 - Filler cap
8 - Seal
❑ Renew if damaged
9 - 22 Nm
10 - Fuel tank
❑ Removing and installing ⇒ page 10
11 - Bush
12 - Fuel tank bracket
13 - 22 Nm
14 - Rubber buffer
15 - Washer
16 - 22 Nm
17 - 22 Nm
18 - Securing strap
❑ With spacer, installation position ⇒ page 7
19 - Retaining clip for heat shield
20 - Heat shield
21 - Retaining clip for heat shield

6 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Installation position of earth connection

– Route earth connection as shown in illustration.
– Ensure that connector for earth connection is securely fitted
on metal ring on fuel filler neck -arrow-.

Caution

After installation, use an ohmmeter to check the electrical con‐

nection between the metal ring on the fuel filler neck and a bare
metal part on the body:
• Specification: approx. 0 Ω.

Installation position of spacers

– Make sure that the securing strap spacers are located directly
under seam of fuel tank -arrow-.

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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.

1.2 Draining fuel tank

Special tools and workshop equipment required
♦ Wrench - T10202-

♦ Fuel extractor - VAS 5190A-

Procedure
Observe safety precautions ⇒ page 1 .

1. Fuel supply system 7

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Observe rules for cleanliness ⇒ page 3 .

WARNING

Switch off ignition and remove ignition key to stop ignition being
switched on inadvertently whilst working.

– Remove luggage compartment floor lining.

– Detach cover for flange (left-side) -arrows-.

– Unplug electrical connectors -1- and -2- at flange.

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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.

– Unscrew locking ring using wrench - T10202- .

– Unscrew cover for flange (right-side) -arrows-.

8 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Unplug electrical connectors -1- and -2- at flange.

– Mark fuel return line -1- and fuel supply line -3-.
– Detach both lines from flange (press release tabs).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– In addition, disconnect fuelpermitted
line -2- leading
unless to by
authorised metering pump
AUDI AG. AUDI AG does not guarantee or accept any liability
for auxiliary heater (press release tab).
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew locking ring using wrench - T10202- .

– Remove luggage compartment side trim cover (right-side)

-arrows-.
– Connect earth wire of fuel extractor -VAS 5190A- to earth stud
of energy management control unit - J644- .

1. Fuel supply system 9

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Remove flange (left-side) and lay it aside with electrical wires

connected.
– Remove seal.
– Extract fuel from left fuel tank chamber through fuel tank open‐
ing using fuel extractor - VAS 5190A- .

– Remove flange (right-side) and lay it aside with electrical wires

and fuel lines connected.
– Remove seal. 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
– Extract fuel from right fuel tank chamber through fuel tank
with respect to the correctness of information in this document. Copyright by AUDI AG.

opening using fuel extractor unit - VAS 5190A- .

– Re-install flange: left-side ⇒ page 53 , right-side
⇒ page 59 .

1.3 Removing and installing fuel tank with attached components

10 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Special tools and workshop

equipment required
♦ Hose clip pliers - V.A.G
1275-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Support - T10031-

Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
• To reduce weight, the fuel tank must be empty when it is re‐
moved from the vehicle. Drain the tank if necessary. Proce‐
dure ⇒ page 7

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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.

1. Fuel supply system 11

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Release the tank flap.

– Clean area around fuel filler neck.
– Remove filler cap -arrow- from fuel filler neck.
– Seal opening of fuel filler neck with a piece of clean foam or
similar to prevent dirt from dropping into the tank.
– Remove rear right wheel housing liner ⇒ Rep. gr. 66 .

WARNING
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
BEFORE loosening subframe bolts, take steps to ensure that
with respect to the correctness of information in this document. Copyright by AUDI AG.
vehicle does not tip forwards (e.g. put a weight of about 50 kg
in luggage compartment).

– Remove rear axle ⇒ Rep. gr. 42 .

– Disconnect earth wire -2- from fuel filler neck.

– Remove bolts -1- and -3- for fuel filler neck.

– Check that propshaft is secured to prevent it falling.

• The propshaft should be placed on a block of wood -1- and
secured with wire or a cable tie -arrow-.
• The propshaft should be inclined slightly downwards to ensure
there is sufficient space when installing the fuel tank.

Note

The propshaft must not be bent more than 8°.

– Remove heat shield for propshaft -arrows-.

Note

The heat shield is also clipped in at the top of the breather pipe.

12 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Remove cover -1- from underside of vehicle (left-side).

– Remove cover -1- from underside of vehicle (right-side).

– Unplug electrical connectors:

1 - To metering pump for auxiliary/additional heater
3 - To fuel pumps
4 - To fuel gauge sendersProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Mark fuel supply line -2-with
and fueltoreturn line -6-.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect the correctness of information in this document. Copyright by AUDI AG.

– Remove hose clips (with lug fasteners) and disconnect both

fuel lines.
– Also disconnect fuel line -5- leading to metering pump for aux‐
iliary heater by removing hose clip (with lug fastener).

– Attach brake calipers to suspension struts with wire -arrow-

(brake calipers were fastened to fuel tank brackets upon re‐
moval of rear suspension).

1. Fuel supply system 13

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Position engine and gearbox jack - V.A.G 1383 A- with support

- T10031- under vehicle to support tank (do not use threaded
rods of support).
– Support fuel tank using engine and gearbox jack -
V.A.G 1383 A- and support - T10031- .
– In addition, a 2nd mechanic will be required to support the fuel
tank at the rear by hand.

WARNING

To reduce weight, fuel tank must be empty upon removal.

– Unscrew bolts -1 ... 6-; swivel fuel tank brackets forward if

necessary.
– First lower fuel tank slightly at the rear so the fuel filler neck
can be guided out of the body.
– Then lower fuel tank using engine and gearbox jack -
V.A.G 1383 A- , simultaneously guiding fuel tank down by
hand.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Illustration permitted
showsunlessfuel authorised
tank without
by AUDI engine
AG. AUDI AGand gearbox
does jack
not guarantee - any liability
or accept
V.A.G 1383 A- with ..
respect to the correctness of information in this document. Copyright by AUDI AG.

Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Always renew seals and gaskets when assembling.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

– Check that fuel pipes and wiring harness for fuel pumps and
fuel gauge senders are clipped into brackets -1- on fuel tank.
– Bond pads -2- to fuel tank as shown when installing new fuel
tank.

14 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Position the fuel tank with securing straps and brackets on

underbody, using the engine and gearbox jack - V.A.G 1383 A-
and support - T10031- .
– When installing fuel tank, make sure that the fuel filler neck is
correctly inserted into the opening on the body.
– Secure fuel tank by first tightening bolts at points -1-, -2-, -5-
and -6-, then at points -3- and -4-.

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

– Make sure that the securing strap spacers are located directly
with respect to the correctness of information in this document. Copyright by AUDI AG.

under seam of fuel tank -arrow-.

– Secure fuel filler neck using bolts -1- and -3-.

– Check the earth wiring -2- and connector tab for traces of ox‐
idation. Remove any traces of oxidation if necessary.

Caution

After installation, use an ohmmeter to check the electrical con‐

nection between the metal ring on the fuel filler neck and a bare
metal part on the body:
• Specification: approx. 0 Ω.

– Secure fuel pipes -2-, -5- and -6- using new hose clips (with
lug fasteners). Use hose clip pliers - V.A.G 1275- for this pur‐
pose.
– Install rear axle ⇒ Rep. gr. 42 .
– Install rear right wheel housing liner ⇒ Rep. gr. 66 .
– Install rear section of exhaust system ⇒ Rep. gr. 26 .
Tightening torques
Component Nm
Securing straps and bracket for fuel tank to body 22
Fuel filler neck to wheel housing 22

1. Fuel supply system 15

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

1.4 Routing of pipes/hoses (inside fuel tank) - overview

Note

♦ The illustration shows the correct routing of pipes/hoses inside the fuel tank (schematic view).
♦ It is not necessary to route the pipes/hoses in exactly the same way as shown in the illustration, except for
pipes/hoses shown in ⇒ page 17 . However it is essential to fit the pipes/hoses with sufficient space in
relation to each other and to prevent rattling noises.
♦ The -arrow- points in direction of travel.

1 - Fuel delivery unit (left-side)

with fuel system pressurisation
pump - G6-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Fuel supply line 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.
❑ From suction-jet pump
(left-side) to fuel deliv‐
ery unit (right-side)
3 - Supply line for suction-jet
pump
❑ From fuel pump (left-
side) to suction-jet
pump (left-side)
4 - Suction-jet pump (left-side)
5 - Gravity valve
6 - Non-return flap
❑ For fuel filler pipe
7 - Primary filling fuel line
❑ To fuel delivery unit
(right-side).
❑ Ensures that a small
amount of fuel is deliv‐
ered immediately to the
fuel delivery unit when
the tank is filled for the
first time.
8 - Suction-jet pump (right-
side)
9 - Supply line for suction-jet
pump
❑ From fuel pump (right-
side) to suction-jet
pump (right-side)
10 - Fuel supply line
❑ From suction-jet pump (right-side) to fuel delivery unit (left-side)
11 - Fuel delivery unit (right-side) with fuel pump - G23-
12 - Fuel return line
❑ From flange to fuel delivery units (left and right)
13 - Breather line
❑ From gravity valve
❑ Open to atmosphere at outside of fuel tank

16 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

14 - Fuel supply line

❑ From fuel pumps (left and right) to flange
15 - Fuel filler pipe
❑ From fuel filler neck to non-return flap in fuel tank

Installation position of fuel supply lines

The supply lines -1- and -3- must be routed below the fuel filler
pipe -2- at the left fuel tank opening.

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.

1.5 Fuel delivery unit (left-side) with fuel system pressurisation pump - G6- ;
fuel gauge sender - G- and fuel gauge sender 3 - G237- - exploded view of
components

1 - Retainer
❑ For fuel delivery unit
2 - Fuel gauge sender - G-
❑ Black
❑ Clipped onto retainer
⇒ Item 1 (page 17)
❑ Checking resistance
values ⇒ page 45
❑ Removing and installing
⇒ page 46
3 - Fuel delivery unit (left-side)
❑ With fuel system pres‐
surisation pump - G6-
❑ Clipped onto retainer
⇒ Item 1 (page 17)
❑ Different versions are
available; allocation ⇒
Parts catalogue
❑ Removing and installing
⇒ page 18
❑ Put at least 5 litres of
fuel into tank after instal‐
ling
4 - Fuel supply line
❑ From suction jet pump
(right-side)
❑ Clipped onto fuel deliv‐
ery unit
⇒ Item 3 (page 17)
5 - Fuel supply line
❑ Press release tab on
connection piece to dis‐

1. Fuel supply system 17

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

connect
6 - Fuel return line
❑ The plug connector is located on the right side of the fuel tank
❑ Press release tab on connection piece to disconnect
7 - Locking ring
❑ Remove and install using wrench - T10202-
❑ Tighten to 120 Nm
8 - Flange (left-side)
❑ Installation position ⇒ page 18
9 - Seal
❑ Renew
❑ Install dry
10 - Supply line for suction-jet pump
❑ For suction-jet pump (left-side)
❑ Press release tab on connection piece to disconnect
11 - Fuel gauge sender 3 - G237-
❑ Grey
❑ Clipped onto fuel delivery unit ⇒ Item 3 (page 17)
❑ Checking resistance values ⇒ page 49
❑ Removing and installing ⇒ page 50

Installation position of flange (left-side)

– Fit new seal for flange in fuel tank opening (seal should be
dry).
– Fit flange into fuel tank; note correct installation position:
• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.

1.6 Removing and

Protected installing
by copyright. fuel
Copying for privatedelivery
or commercial purposes, in part or in whole, is not

unit (left-side) with fuel system pressur‐

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.

isation pump - G6-

Special tools and workshop equipment required
♦ Wrench - T10202-

18 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
• The fuel tank must not be more than 1/3 full when removing
the fuel delivery unit. Drain the tank if necessary. Procedure
⇒ page 7

Note

For removing and installing fuel delivery unit, take tool kit and
spare wheel out of luggage compartment. You can then sit or
kneel in the spare wheel well.

– Remove luggage compartment floor lining.

– Detach cover for flange (left-side) -arrows-.

– Unplug electrical connectors -1- and -2- at flange.

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.

– Unscrew locking ring using wrench - T10202- .

1. Fuel supply system 19

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Detach flange and remove seal.

– Detach electrical connectors -1 ... 4- at underside of flange.

– Unscrew cover for flange (right-side) -arrows-.

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
– Unplug electrical connectors -1- and -2- at flange.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Mark fuel return line -1- and fuel supply line -3-.
– Detach both lines from flange (press release tabs).
– In addition, disconnect fuel line -2- leading to metering pump
for auxiliary heater (press release tab).

20 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Unscrew locking ring using wrench - T10202- .

– Detach flange and remove seal.

– Detach electrical connectors -1 ... 4- at underside of flange.

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.

Note

♦ Pull out fuel lines from fuel tank opening prior to disconnecting
the pipe connectors mentioned below.
♦ Some of the components are shown removed in the following
illustration.

– Pull out suction pipe -1- for auxiliary heater from retainer
-arrows- on tubular sender (right-side).

1. Fuel supply system 21

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Working through right fuel tank opening, press release tab and
disconnect fuel line -1- going to fuel delivery unit (left-side).
– Pull disconnected fuel line out of left fuel tank opening.
2 - Fuel delivery unit (right-side) with fuel pump - G23- .

Note

Disregard -item 3-.

– Working through left fuel tank opening, press release tab and
disconnect fuel line -1- going to suction-jet pump (left-side).
– Disconnect fuel line -2- going to fuel delivery unit (right-side)
by pressing release tab.
3 - Fuel delivery unit (left-side) with fuel system pressurisation
pump - G6- .

– Working through left fuel tank opening, press release tabs

-arrows- and detach supply line -2- and fuel gauge sender 3 -
G237- -item 1-.
– Move fuel gauge sender 3 - G237- to left side.

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.

22 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Press down both retaining clips on retainer for fuel delivery unit
(left-side) -arrows-.
– Remove fuel delivery unit.

Note

Keep in mind that the fuel delivery unit still contains fuel.
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.

Installing
– Pull both retaining clips on retainer upwards -arrows- so that
they engage audibly before installing the fuel delivery unit (left-
side).
– Then press fuel delivery unit carefully into retainer so that it
engages audibly.

– Fit fuel supply line -2- and fuel gauge sender 3 - G237-
-item 1- so that they engage audibly.

– Fit fuel lines -1- and -2- through left fuel tank opening so that
they engage audibly.
– Guide return line for fuel delivery unit (left-side) into fuel tank
chamber (right-side).
3 - Fuel delivery unit (left-side) with fuel system pressurisation
pump - G6- .

1. Fuel supply system 23

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Working through right fuel tank opening, fit fuel line -1- so that
it engages audibly.
2 - Fuel delivery unit (right-side) with fuel pump - G23- .

– Fit suction pipe -1- for auxiliary heater into retainers -arrows-
on tubular sender (right-side).

– Connect electrical connectors -1 ... 4- at underside of flange.

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.

24 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Fit new seal for flange in fuel tank opening (seal should be
dry).
– Fit flange (right-side) into fuel tank; note correct installation
position:
• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.

– Tighten locking ring.

– Fit fuel return line -1- and fuel supply line -3- so that they en‐
gage audibly.
– Also fit supply line -2- going to auxiliary heater so that it en‐
gages audibly.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach electrical connectors -1- and -2- at flange.
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.

1. Fuel supply system 25

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Secure cover for flange (right-side) -arrows-.

– Connect electrical connectors -1 ... 4- on underside of flange

(left-side). 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.

– Fit new seal for flange in fuel tank opening (seal should be
dry).
– Fit flange into fuel tank; note correct installation position:
• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.

– Tighten locking ring.

26 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Attach electrical connectors -1- and -2- at flange.

– Secure cover for flange (left-side) -arrows-.

– Put at least 5 litres of fuel into tank after installing fuel delivery
unit.
– Vehicles with auxiliary heater: Let auxiliary heater run with full
load for 10 minutes to bleed fuel line leading to metering pump.
Tightening torque
Component Nm
Locking ring for fuel delivery unit 120

1.7 Fuel delivery unit (right-side) with fuel pump - G23- ; fuel gauge sender 2 -
G169- and fuel gauge sender 4 - G393- - exploded view of components

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.

1. Fuel supply system 27

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

1 - Retainer
❑ For fuel delivery unit
2 - Fuel gauge sender 2 -
G169-
❑ Yellow
❑ Clipped onto retainer
⇒ Item 1 (page 28)
❑ Checking resistance
values ⇒ page 47
❑ Removing and installing
⇒ page 48
3 - Fuel gauge sender 4 -
G393-
❑ White
❑ Clipped onto fuel deliv‐
ery unit
⇒ unless
Itemauthorised
15 (page 29)AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted by AUDI
❑with respect
Checking resistance
to the correctness of information in this document. Copyright by AUDI AG.
values ⇒ page 54
❑ Removing and installing
⇒ page 56
4 - Supply line for suction-jet
pump
❑ For suction-jet pump
(right-side)
❑ Press release tab on
connection piece to dis‐
connect
5 - Fuel supply line
❑ To fuel filter
❑ Mark before removing
❑ Press release tab on
connection piece to dis‐
connect
❑ Do not kink
❑ Clip onto fuel tank
6 - Fuel line
❑ To auxiliary heater
❑ Press release tab on connection piece to disconnect
❑ Do not kink
❑ Clip onto fuel tank
7 - Fuel return line
❑ From fuel cooler
❑ Mark before removing
❑ Press release tab on connection piece to disconnect
❑ Do not kink
❑ Clip onto fuel tank
8 - Locking ring
❑ Remove and install using wrench - T10202-
❑ Tighten to 120 Nm
9 - Seal
❑ Renew

28 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

❑ Install dry
10 - Flange (right-side)
❑ Installation position ⇒ page 29
11 - Fuel supply line
❑ From fuel pumps (left and right) to flange
❑ Press release tab on connection piece to disconnect
12 - Fuel return line
❑ From flange to fuel delivery units (left and right)
❑ Press release tab on connection piece to disconnect
13 - Fuel supply line
❑ From suction-jet pump (left-side)
❑ Clipped onto fuel delivery unit ⇒ Item 15 (page 29)
14 - Fuel filler pipe
❑ From filler neck
❑ Clipped onto fuel delivery unit ⇒ Item 15 (page 29)
15 - Fuel delivery unit (right-side)
❑ With fuel pump - G23-
❑ Clipped onto retainer ⇒ Item 1 (page 28)
❑ Different versions are available; allocation ⇒ Parts catalogue
❑ Removing and installing ⇒ page 29
❑ Put at least 5 litres of fuel into tank after installing

Installation position of flange (right-side)

– Fit new seal for flange in fuel tank opening (seal should be
dry).
– Fit flange into fuel tank; note correct installation position:
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
• Lug -2- on flange must be between tabs -1- and -3- on fuel
with respect to the correctness of information in this document. Copyright by AUDI AG.

tank.

1.8 Removing and installing fuel delivery

unit (right-side) with fuel pump - G23-
Special tools and workshop equipment required
♦ Wrench - T10202-

1. Fuel supply system 29

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
• The fuel tank must not be more than 1/3 full when removing
the fuel delivery unit. Drain the tank if necessary. Procedure
⇒ page 7

Note

For removing and installing fuel delivery unit, take tool kit and
spare wheel out of luggage compartment. You can then sit or
kneel in the spare wheel well.

– Remove luggage compartment floor lining.

– Unscrew cover for flange (right-side) -arrows-.

– Unplug electrical connectors -1- and -2- at flange.

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.

– Mark fuel return line -1- and fuel supply line -3-.
– Detach both lines from flange (press release tabs).
– In addition, disconnect fuel line -2- leading to metering pump
for auxiliary heater (press release tab).

30 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Unscrew locking ring using wrench - T10202- .

– Detach flange and remove seal.

– Detach electrical connectors -1 ... 4- at underside of flange.

Note

♦ Pull out fuel lines from fuel tank opening prior toProtected
disconnecting
by copyright. Copying for private or commercial purposes, in part or in whole, is not
the pipe connectors mentioned below. 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.
♦ Some of the components are shown removed in the following
illustration.

– Pull out suction pipe -1- for auxiliary heater from retainer
-arrows- on tubular sender (right-side).

1. Fuel supply system 31

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Working through right fuel tank opening, press release tab and
disconnect fuel line -1- going to fuel delivery unit (left-side).
– Press release tab and disconnect fuel line -3- going to suction
jet pump (right-side).
2 - Fuel delivery unit (right-side) with fuel pump - G23- .

– Unclip fuel filler pipe -arrow- at front of fuel delivery unit (right-
side).

– Detach cover for flange (left-side) -arrows-.

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.
– Unplug electrical connectors -1- and -2- at flange.

32 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Unscrew locking ring using wrench - T10202- .

– Detach flange and remove seal.

– Detach electrical connectors -1 ... 4- at underside of flange.

– Working through left fuel tank opening, press release tab and
disconnect fuel supply line -2- going to fuel delivery unit (right-
side).
– Pull disconnected fuel supply line out of the right fuel tank
opening.
3 - Fuel delivery unit (left-side) with fuel system pressurisation
pump - G6- .

Note

Disregard -item 1-.

– Working through right fuel tank opening, press release tabs

-arrows- and detach supply line -1- and fuel gauge sender 4 -
G393- -item 2-.
– Move fuel gauge sender 4 - G393- to right side.

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.

1. Fuel supply system 33

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Press down both retaining clips on retainer for fuel delivery unit
(right-side) -arrows-.
– Remove fuel delivery unit.

Note

Keep in mind that the fuel delivery unit still contains fuel.

Installing
– Pull both retaining clips on retainer upwards -arrows- so that
they engage audibly before installing fuel delivery unit (right-
side).
– Then press fuel delivery unit carefully into retainer so that it
engages audibly.

– Fit fuel supply line -1- and fuel gauge sender 4 - G393-
-item 2- so that they engage audibly on fuel delivery unit (right-
side).

– Fit fuel lines -2- through left opening on fuel tank so that they
engage audibly.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Fuel delivery unit (left-side)
permittedwith
unlessfuel system
authorised pressurisation
by AUDI AG. AUDI AG does not guarantee or accept any liability
pump - G6- . with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Disregard -item 1-.

34 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Connect electrical connectors -1 ... 4- at underside of flange.

– Fit new seal for flange in fuel tank opening (seal should be
dry).
– Fit flange (left-side) into fuel tank; note correct installation po‐
sition:
• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.

– Tighten locking ring.

– Attach electrical connectors -1- and -2- at flange.

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.

1. Fuel supply system 35

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Secure cover for flange -arrows-.

– Fit fuel lines -1- and -3- through right fuel tank opening so that
they engage audibly.
2 - Fuel delivery unit (right-side) with fuel pump - G23- .

– Fit suction pipe -1- for auxiliary heater into retainers -arrows-
on tubular sender (right-side).

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.

36 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Connect electrical connectors -1 ... 4- at underside of flange.

– Fit newProtected
seal for by flange
copyright. in fuelfortank
Copying opening
private (seal
or commercial should
purposes, in partbe
or in whole, is not
dry). 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.
– Fit flange (right-side) into fuel tank; note correct installation
position:
• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.

– Tighten locking ring.

– Fit fuel return line -1- and fuel supply line -3- so that they en‐
gage audibly.
– Also fit supply line -2- going to auxiliary heater so that it en‐
gages audibly.

1. Fuel supply system 37

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Attach electrical connectors -1- and -2- at flange.

– Secure cover for flange (right-side) -arrows-.

– Put at least 5 litres of fuel into tank after installing fuel delivery
unit.
– Vehicles with auxiliary heater: Let auxiliary heater run with full
load for 10 minutes to bleed fuel line leading to metering pump.
Tightening torque
Component Nm
Locking ring for fuel delivery unit 120

1.9 Checking fuel pump delivery rate

Special tools and workshop equipment required
♦ Remote control - V.A.G 1348/3A- for V.A.G 1348 with adapter
cable - V.A.G 1348/3-2-

♦ Fuel-resistant measuring container

Test sequence
– Observe test conditions ⇒ page 3 .
– If fitted, remove cover for suspension turret (right-side); to do
so, detach spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Caution
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.

Rules for cleanliness when working on the injection system

⇒ page 3 .

38 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Disconnect fuel supply line -2- going to engine at fuel filter.

Note

Disregard -item 1-.

– Fit auxiliary hose -arrow- onto connection at fuel filter and hold
it into a measuring container to catch fuel.

– Remove luggage compartment side trim cover (right-side)

-arrows-.

– Disconnect fuel pump relay - J17- located at position -3- on

relay and fuse holder in luggage compartment (right-side).

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.

1. Fuel supply system 39

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Connect remote control - V.A.G 1348/3 A- with adapter cable

- V.A.G 1348/3-2- to contact 2 -arrow- in fuel pump relay sock‐
et.
– Connect crocodile clip of remote control - V.A.G 1348/3 A- to
vehicle battery “+” (positive).

– Press remote control button for 15 seconds.

– Compare amount of fuel delivered with minimum delivery
shown in diagram (cm3/15 sec.).

Note

Voltage at fuel pump with engine stationary and pump running is

approx. 2 volts less than battery voltage.

If minimum delivery rate is not reached, check for the following

causes:
♦ Fuel lines have been crushed.
♦ Fuel filter is blocked.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Fuel pumps
permittedare defective.
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.

Note

As there is hardly any difference in the delivery rate if only one of

the two fuel pumps is working – because of the hose connections
inside the tank – it is difficult to diagnose a defective pump by just
measuring the delivery rate.

In this case proceed as follows:

– Unplug electrical connector for fuel delivery unit (left-side).
– Measure delivery rate.
– Unplug electrical connector for fuel delivery unit (right-side).
– Measure delivery rate.
– If delivery rate differs considerably from specification, renew
relevant fuel delivery unit.

1.10 Suction-jet pumps: operation

40 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

1 - Suction-jet pump (left-side)

2 - Fuel delivery unit (left-side)
3 - Fuel delivery unit (right-
side)
4 - Suction-jet pump (right-
side)
5 - Fuel pump (right-side)
6 - Fuel pump (left-side)
Description of operation
To ensure a reliable fuel supply
in all situations, the fuel pumps
must never draw in air, even
under extreme driving condi‐
tions such as very sharp bends
or under heavy braking. This
may happen when the fuel
sloshes into one of the corners
of a partially filled fuel tank.
♦ For this reason, the fuel de‐
livery units
⇒ Item 2 (page 41) and
⇒ Item 3 (page 41) incorpo‐
rate a so-called baffle hous‐
ing, into which the fuel
pumps are inserted, as well
as the fuel pumps them‐
selves. The baffle housing
is a container permanently
filled with fuel, so that the
fuel pumps are surrounded
with fuel regardless of the
fuel level in the tank.
♦ Consequently, proper filling
of the baffle housings is es‐
sential for trouble-free op‐
eration of the fuel pumps.
This is the purpose of the suction jet pumps.
♦ The suction-jet pumps operate according to the principle of fluid entrainment: a stream of fuel from the
primary stage of the fuel pump (right-side) ⇒ Item 5 (page 41) or (left-side) ⇒ Item 6 (page 41) is passed
through a nozzle in the suction-jet pumps ⇒ Item 4 (page 41) and ⇒ Item 1 (page 41) , and is thus accelerated.
The accelerated stream of fuel draws off the surrounding fuel and delivers it to the baffle housings in the
fuel delivery units. The suction jet pump (right-side) ⇒ Item 4 (page 41) delivers the fuel to the baffle housing
(left-side); the suction jet pump (left-side) ⇒ Item 1 (page 41) delivers the fuel to the baffle housing (right-
side).

1.11 Removing and installing suction-jet

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

pump (left-side) with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
– Remove the fuel delivery unit (left-side) ⇒ page 18 .
– Remove fuel gauge sender 3 - G237- (tubular sender, left-
side) from fuel tank.

1. Fuel supply system 41

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Working through right fuel tank opening, press release tabs

-arrows- and detach fuel supply line -1-.

Note

Disregard -item 2-.

– Pull out disconnected fuel supply line -1- through left fuel tank
opening.

– Working through left fuel tank opening, press release tab

-arrow- and detach retaining clip for suction jet lines from re‐
tainer.
– Pull out suction-jet pump (left-side) together with lines through
left fuel tank opening.

Installing
– Insert suction-jet pump (left-side) -1- into fuel tank and place
into recess in baffle plate -2- in fuel tank at front, as shown in
illustration.
– Then press retaining clip for bysuction-jet
Protected pump
copyright. Copying into orretainer
for private so
commercial purposes, in part or in whole, is not
it engages audibly. 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.

– Push fuel supply line -3- through left fuel tank opening into right
fuel tank chamber. Note routing:
• The supply line -3- must be routed below the fuel filler pipe
-2- at the left fuel tank opening.

Note

Disregard -item 1-.

42 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Fit fuel supply line -1- onto fuel delivery unit (right-side) so that
the locking hooks engage audibly.

Note

Disregard -item 2-.

– Insert fuel gauge sender 3 - G237- (tubular sender, left-side)

into fuel tank.
– Install fuel delivery unit (left-side) ⇒ page 23 .

1.12 Removing and installing suction-jet

pump (right-side)
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
– Remove fuel delivery unit (right-side) ⇒ page 29 .
– Remove fuel gauge sender 4 - G393- (tubular sender, right-
side) from fuel tank.
– Working through left fuel tank opening, press release tabs
-arrows- and detach fuel supply line -2-.

Note

Disregard -item 1-.

– Pull out disconnected fuel supply line -2- from right fuel tank
opening.

– Working through right fuel tank opening, press release tab

-arrow- and detach retaining clip for
Protected suctionCopying
by copyright. jet lines from
for private re‐
or commercial purposes, in part or in whole, is not
tainer. 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.
– Pull suction-jet pump (right-side) together with lines out of right
fuel tank opening.

1. Fuel supply system 43

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Installing
– Insert suction-jet pump (right-side) -1- into fuel tank and place
into recess in baffle plate -2- in fuel tank at front, as shown in
illustration.
– Then press retaining clip for suction-jet pump into retainer so
it engages audibly.

– Push fuel supply line -1- through right fuel tank opening into
left fuel tank chamber. Note routing:
• The supply line -1- must be routed below the fuel filler pipe
-2- at the left fuel tank opening.
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.
Note

Disregard -item 3-.

– Fit fuel supply line -2- onto fuel delivery unit (left-side) so that
the locking hooks engage audibly.

Note

Disregard -item 1-.

– Insert fuel gauge sender 4 - G393- (tubular sender, right-side)

into fuel tank.
– Install fuel delivery unit (right-side) ⇒ page 34 .

44 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

2 Fuel gauge senders

⇒ “2.1 Checking fuel gauge sender G (lever-type sender, left-
side)”, page 45
⇒ “2.2 Removing and installing fuel gauge sender G (lever-type
sender, left-side)”, page 46
⇒ “2.3 Checking fuel gauge sender 2 G169 (lever-type sender,
right-side)”, page 47
⇒ “2.4 Removing and installing fuel gauge sender 2 G169 (lever-
type sender, right-side)”, page 48
⇒ “2.5 Checking fuel gauge sender 3 G237 (tubular sender, left-
side)”, page 49
⇒ “2.6 Removing and installing fuel gauge sender 3 G237 (tubular
sender, left-side)”, page 50
⇒ “2.7 Checking fuel gauge sender 4 G393 (tubular sender, right-
side)”, page 54
⇒ “2.8 Removing and installing fuel gauge sender 4 G393 (tubular
sender, right-side)”, page 56

2.1 Checking fuel gauge sender - G- (lever-

type sender, left-side)
Special tools and workshop equipment required
♦ Hand-held multimeter - V.A.G 1526 E-

♦ Auxiliary measuring set - V.A.G 1594 C-

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.

2. Fuel gauge senders 45

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Test sequence
– Remove luggage compartment floor lining.
– Detach cover for flange (left-side) -arrows-.

– Unplug electrical connector -1- at flange.

Note

Disregard -item 2-.

– Connect hand-held multimeter - V.A.G 1526 E- between con‐

tacts -2- and -4- of connector -B- to measure resistance.
Sender installed Sender at low‐ Sender at up‐
er stop per stop
Fuel gauge sender - G- approx. 700 Ω approx. 55 Ω
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.

Note

♦ If the resistance is 0 Ω, there is a short circuit. If the resistance

is ∞ Ω, there is an open circuit in the wiring.
♦ In order to test the maximum and minimum resistance values
for “tank full” and “tank empty”, remove the fuel gauge sender
- G- ⇒ page 46 and move the float all the way to its top or
bottom position.
♦ The following values are obtained with the fuel gauge sender
- G- removed, due to the greater travel of the float arm:

Sender removed Sender at low‐ Sender at up‐

er stop per stop
Fuel gauge sender - G- approx. 990 Ω approx. 55 Ω
Assemble in reverse order.

2.2 Removing and installing fuel gauge

sender - G- (lever-type sender, left-side)
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .

46 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

• The fuel tank must be drained completely before removing the

lever-type sender. Procedure for draining the fuel tank
⇒ page 7 .
– Remove the fuel delivery unit (left-side) ⇒ page 18 .
– Remove fuel gauge sender 3 - G237- (tubular sender, left-
side) from fuel tank.
– Release fuel gauge sender - G- -arrow- and detach from re‐
tainer.
Installing
– Press fuel gauge sender - G- into retainer so that it engages
audibly.
– Insert fuel gauge sender 3 - G237- into fuel tank.
– Install fuel delivery unit (left-side) ⇒ page 23 .

2.3 Checking fuel gauge sender 2 - G169-

(lever-type sender, right-side)
Special tools and workshop equipment required
♦ Hand-held multimeter - V.A.G 1526 E-

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.

♦ Auxiliary measuring set - V.A.G 1594 C-

2. Fuel gauge senders 47

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Test sequence
– Remove luggage compartment floor lining.
– Unscrew cover for flange (right-side) -arrows-.

– Unplug electrical connector -1- at flange.

Note

Disregard -item 2-.

– Connect hand-held multimeter - V.A.G 1526 E- between con‐

tacts -2- and -4- of connector -B- to measure resistance.
Sender installed Sender at low‐ Sender at up‐
er stop per stop
Fuel gauge sender 2 - G169- approx. 750 Ω approx. 55 Ω

Note

♦ If the resistance is 0 Ω, there is a short circuit. If the resistance

is ∞ Ω, there is an open circuit in the wiring.
♦ In order to test the maximum and minimum values for “tank
full” and “tank empty”, remove the fuel gauge sender 2 - G169-
⇒ page 48 and move the float all the way to its top or bottom
position.
♦ The following values are obtained with the fuel gauge sender 2
- G169- removed, due to the greater travel of the float arm:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Sender removed
permitted unlessSender
authorised at low‐AG.Sender
by AUDI AUDI AG doesat up‐
not guarantee or accept any liability
er stop per stop
with respect to the correctness of information in this document. Copyright by AUDI AG.

Fuel gauge sender 2 - G169- approx. 990 Ω approx. 55 Ω

2.4 Removing and installing fuel gauge

sender 2 - G169- (lever-type sender,
right-side)
Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .

48 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

• The fuel tank must be drained completely before removing the

lever-type sender. Procedure for draining the fuel tank
⇒ page 7 .
– Remove fuel delivery unit (right-side) ⇒ page 29 .
– Remove fuel gauge sender 4 - G393- (tubular sender, right-
side) from fuel tank.
– Release fuel gauge sender 2 - G169- -arrow- and detach from
retainer.
Installing
– Press fuel gauge sender 2 - G169- into retainer so that it en‐
gages audibly.
– Insert fuel gauge sender 4 - G393- into fuel tank.
– Install fuel delivery unit (right-side) ⇒ page 34 .

2.5 Checking fuel gauge sender 3 - G237-

(tubularProtected
sender,
permitted unless left-side)
by copyright. Copying for private or commercial purposes, in part or in whole, is not
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.
Special tools and workshop equipment required
♦ Hand-held multimeter - V.A.G 1526 E-

♦ Auxiliary measuring set - V.A.G 1594 C-

2. Fuel gauge senders 49

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Test sequence
– Remove luggage compartment floor lining.
– Detach cover for flange (left-side) -arrows-.

– Unplug electrical connector -2- at flange.

Note

Disregard -item 1-.

– Connect hand-held multimeter - V.A.G 1526 E- between con‐

tacts -2- and -3- of connector -A- to measure resistance.
Sender removed Sender at low‐ Sender at up‐
er stop per stop
Fuel gauge sender 3 - G237- approx. 155 Ω approx. 70 Ω
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.
Note

♦ If the resistance is 0 Ω, there is a short circuit. If the resistance

is ∞ Ω, there is an open circuit in the wiring.
♦ In order to test the maximum and minimum values for “tank
full” and “tank empty”, remove the fuel gauge sender 3 - G237-
⇒ page 50 and move the float all the way to its top or bottom
position.

2.6 Removing and installing fuel gauge

sender 3 - G237- (tubular sender, left-
side)
Special tools and workshop equipment required

50 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

♦ Wrench - T10202-

Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
• The left fuel tank chamber must not be more than 1/3 full when
removing the tubular sender. Procedure for draining the fuel
tank ⇒ page 7 .
– Briefly open filler cap for fuel tank and close again.

Note

For removing and installing tubular sender, take tool kit and spare
wheel out of luggage compartment. You can then sit or kneel in
the spare wheel well.

– Remove luggage compartment floor lining.

– Detach cover for flange (left-side) -arrows-.

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.

– Unplug electrical connectors -1- and -2- at flange.

2. Fuel gauge senders 51

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Unscrew locking ring using wrench - T10202- .

– Detach flange and remove seal.

– Detach electrical connectors -1 ... 4- at underside of flange.

– Working through left fuel tank opening, press release tabs

-arrows- and detach supply line -2- and fuel gauge sender 3 -
G237- -item 1-.
– Move fuel gauge sender 3 - G237- to left side.

– Press down both retaining clips on retainer for fuel delivery unit
(left-side) -arrows-.
– Pull fuel delivery unit slightly upwards and at the same time
take out fuel gauge sender 3 - G237- .
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
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

Keep in mind that the fuel gauge sender 3 - G237- still contains
fuel.

52 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Installing
– Pull both retaining clips on retainer upwards -arrows- so that
they engage audibly before installing the fuel delivery unit (left-
side).
– Then press fuel delivery unit carefully into retainer so that it
engages audibly.

– Fit fuel supply line -2- and fuel gauge sender 3 - G237-
-item 1- so that they engage audibly.

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.

– Connect electrical connectors -1 ... 4- at underside of flange.

– Fit new seal for flange in fuel tank opening (seal should be
dry).
– Fit flange (left-side) into fuel tank; note correct installation po‐
sition:
• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.

2. Fuel gauge senders 53

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Tighten locking ring.

– Attach electrical connectors -1- and -2- at flange.

– Secure cover for flange (left-side) -arrows-.

Tightening torque
Component Protected by copyright.Nm
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
Locking ring for fuel delivery unit with respect to the 120
correctness of information in this document. Copyright by AUDI AG.

2.7 Checking fuel gauge sender 4 - G393-

(tubular sender, right-side)
Special tools and workshop equipment required
♦ Hand-held multimeter - V.A.G 1526 E-

54 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

♦ Auxiliary measuring set - V.A.G 1594 C-

Test sequence
– Remove luggage compartment floorProtected
lining.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
– Unscrew cover for flange (right-side) -arrows-.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unplug electrical connector -2- at flange.

Note

Disregard -item 1-.

– Connect hand-held multimeter - V.A.G 1526 E- between con‐

tacts -2- and -3- of connector -A- to measure resistance.
Sender removed Sender at low‐ Sender at up‐
er stop per stop
Fuel gauge sender 4 - G393- approx. 155 Ω approx. 70 Ω

Note

♦ If the resistance is 0 Ω, there is a short circuit. If the resistance

is ∞ Ω, there is an open circuit in the wiring.
♦ In order to test the maximum and minimum values for “tank
full” and “tank empty”, remove the fuel gauge sender 4 - G393-
⇒ page 56 and move the float all the way to its top or bottom
position.

2. Fuel gauge senders 55

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

2.8 Removing and installing fuel gauge

sender 4 - G393- (tubular sender, right-
side)
Special tools and workshop equipment required
♦ Wrench - T10202-

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.

Removing
Observe safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 3 .
• The right fuel tank chamber must not be more than 1/3 full
when removing the tubular sender. Procedure for draining the
fuel tank ⇒ page 7 .
– Briefly open filler cap for fuel tank and close again.

Note

For removing and installing tubular sender, take tool kit and spare
wheel out of luggage compartment. You can then sit or kneel in
the spare wheel well.

– Remove luggage compartment floor lining.

– Unscrew cover for flange (right-side) -arrows-.

56 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Unplug electrical connectors -1- and -2- at flange.

– Mark fuel return line -1- and fuel supply line -3-.
– Detach both lines from flange (press release tabs).
– In addition, disconnect fuel line -2- leading to metering pump
for auxiliary heater (press release tab).

– Unscrew locking ring using wrench - T10202- .

– Detach flange and remove seal.

– Detach electrical connectors -1 ... 4- at underside of flange.

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.

2. Fuel gauge senders 57

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Note

♦ Pull out fuel lines from fuel tank opening prior to disconnecting
the pipe connectors mentioned below.
♦ Some of the components are shown removed in the following
illustration.

– Pull out suction pipe -1- for auxiliary heater from retainer
-arrows- on tubular sender (right-side).

– Working through right fuel tank opening, press release tab and
disconnect fuel lines -1- and -3-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Fuel delivery unit (right-side)
permitted with fuel
unless authorised pump
by AUDI - G23-
AG. AUDI . not guarantee or accept any liability
AG does
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Working through right fuel tank opening, press release tabs

-arrows- and detach supply line -1- and fuel gauge sender 4 -
G393- -item 2-.
– Move fuel gauge sender 4 - G393- to right side.

58 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Press down both retaining clips on retainer for fuel delivery unit
(right-side) -arrows-.
– Pull fuel delivery unit slightly upwards and at the same time
take out fuel gauge sender 4 - G393- .

Note

Keep in mind that the fuel gauge sender 4 - G393- still contains
fuel. 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.

Installing
– Pull both retaining clips on retainer upwards -arrows- so that
they engage audibly before installing fuel delivery unit (right-
side).
– Then press fuel delivery unit carefully into retainer so that it
engages audibly.

– Fit fuel supply line -1- and fuel gauge sender 4 - G393-
-item 2- so that they engage audibly.

2. Fuel gauge senders 59

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Fit fuel lines -1- and -3- through right fuel tank opening so that
they engage audibly.
2 - Fuel delivery unit (right-side) with fuel pump - G23- .

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.

– Fit suction pipe -1- for auxiliary heater into retainers -arrows-
on tubular sender (right-side).

– Connect electrical connectors -1 ... 4- at underside of flange.

60 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Fit new seal for flange in fuel tank opening (seal should be
dry).
– Fit flange (right-side) into fuel tank; note correct installation
position:
• Lug -2- on flange must be between tabs -1- and -3- on fuel
tank.

– Tighten locking ring.

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.

– Fit fuel return line -1- and fuel supply line -3- so that they en‐
gage audibly.
– Also fit supply line -2- going to auxiliary heater so that it en‐
gages audibly.

– Attach electrical connectors -1- and -2- at flange.

2. Fuel gauge senders 61

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Secure cover for flange -arrows-.

Tightening torque
Component Nm
Locking ring for fuel delivery unit 120

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.

62 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

3 Fuel cooler
⇒ “3.1 Removing and installing fuel cooler on underbody”,
page 63
⇒ “3.2 Removing and installing fuel cooler on engine - vehicles
with 8-cylinder 4.0 ltr. TDI engine”, page 64

3.1 Removing and installing fuel cooler on

underbody
Special tools and workshop equipment required
♦ Hose clip pliers - V.A.G 1275-

♦ Drip tray
Removing
Observe rules for cleanliness ⇒ page 3 .
– Remove cover -1- on rear right side of fuel tank.

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.

– Remove underbody cover (right-side) -arrows-.

3. Fuel cooler 63
 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Place drip tray below underbody.

– Disconnect fuel return line -1- from rear of fuel cooler and catch
escaping fuel.
– Remove bolts -2-.

– Unscrew bolt -2- for the front bracket for the fuel lines.
– Remove bolts -1-.

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.

– Move fuel cooler -2- to side and down and remove fuel return
line -1- at front of fuel cooler.
– Unclip fuel supply lines -arrows- using a screwdriver and de‐
tach fuel cooler.
Installing
Installation is carried out in the reverse order; note the following:

Note

Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

Tightening torques
Component Nm
Fuel cooler to underbody 1.75
Cover to underbody 2.3

3.2 Removing and installing fuel cooler on

engine - vehicles with 8-cylinder 4.0 ltr.
TDI engine
Special tools and workshop equipment required

64 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

♦ Hose clip pliers - V.A.G 1275-

Removing
Observe rules for cleanliness ⇒ page 3 .

Note

The fuel cooler is located under the high-pressure pump (on the
engine).

– Remove high-pressure pump with front bracket ⇒ Rep. gr.

13 .
– Disconnect fuel return hose -1- at fuel cooler.
– Detach coolant hoses -2- and -3- at fuel cooler.
– Remove bolts -arrows-.
– Remove fuel cooler.
Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Always renew seals and gaskets when assembling.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

– Install high-pressure pump with front bracket ⇒ Rep. gr. 13 .

Tightening torque
Component Nm
Fuel cooler to mounting plate 10
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.

3. Fuel cooler 65
 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

4 Servicing fuel filter

⇒ “4.1 Fuel filter - exploded view of components”, page 66
⇒ “4.2 Removing and installing fuel filter”, page 67

4.1 Fuel filter - exploded view of components

1 - Bracket
❑ For fuel filter
2 - 10 Nm
3 - O-ring
❑ Inserted in filter housing
4 - Regulating valve
❑ Installation position: ar‐
row points towards fuel
tank
❑ When changing filter,
remove retaining clip
and take regulating
valve off with fuel lines
connected
❑ Make sure O-ring in filter
housing is in correct po‐
sition when fitting regu‐
lating valve
❑ Temperatures below
approx. 60 °C: Passage
to filter open
❑ Temperatures above
approx. 70 °C: Passage
to filter closed
5 - Return line
❑ To fuel cooler
❑ Blue marking
6 - Supply line
❑ From fuel tank
❑ White marking
7 - Spring-type clip
8 - Bleeder screw, 4 Nm
9 - Seal
❑ Renew
10 - Retaining clip
❑ Renew after removing
11 - Fuel filter
❑ Flow direction is marked by arrows
❑ Do not interchange connections
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew filter at intervals specified inunless
permitted Service Schedule
authorised by AUDI AG. ⇒ AUDI
Maintenance ; Booklet
AG does not guarantee 404
or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ With seal for regulating valve
12 - Supply line
❑ To high-pressure pump
❑ White marking

66 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

13 - Return line
❑ From engine
❑ Blue marking
14 - 10 Nm

4.2 Removing and installing fuel filter

Removing
Observe rules for cleanliness ⇒ page 3 .

Note

♦ Fitting location of fuel filter: at rear right of engine compart‐

ment.
♦ Please ensure that no diesel fuel contacts coolant hoses. If
necessary clean hoses immediately.
♦ Please observe requirements for disposal.

– If fitted, remove cover for suspension turret (right-side); to do

so, detach spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.

– Detach retaining clip -1-.

– Detach regulating valve -5- with fuel pipes still connected.
– Disconnect fuel hoses -2- and -3- from hose connections.
– Slacken clamping bolt -4- at bracket and remove fuel filter from
bracket.
Installing
Installation is carried out in the reverse order; note the following:

Note 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.
♦ Always renew seals, retaining clips and gaskets when assem‐
bling.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .

– Fill new filter with clean diesel fuel. This will enable the engine
to start more quickly.

– Fit fuel filter in bracket and tighten clamping bolt -4- to 10 Nm.
– Make sure O-ring in filter housing is in correct position when
fitting regulating valve -5-.
– Install regulating valve with fuel lines connected.
– Attach retaining clip -1-.
– Push fuel hoses -2- and -3- onto hose connections and secure
with hose clips.

4. Servicing fuel filter 67

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

5 Bleeding fuel system

Due to the design of the engine, with a fuel system pressurisation
pump located in the fuel tank, it is not necessary to bleed the fuel
system.
The fuel system bleeds itself when the starter is operated.

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.

68 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

6 Checking fuel system for leaks

⇒ “6.1 Checking fuel system for leaks (vehicles with 6-cyl. TDI
engine)”, page 69
⇒ “6.2 Checking fuel system for leaks (vehicles with 8-cyl. 4.0 ltr.
TDI engine)”, page 70
⇒ “6.3 Checking fuel system for leaks (vehicles with 8-cyl. 4.2 ltr.
TDI engine)”, page 72

6.1 Checking fuel system for leaks (vehicles

with 6-cyl. TDI engine)
A leaking fuel system can cause:
♦ Foam build-up or air bubbles in the supply line
♦ Lack of power, misfiring
♦ Starting problems
Special tools and workshop equipment required
♦ Hose clamps, up to 25 mm - 3094-

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.

♦ Cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/1 A- and adapter for testing diesel fuel - V.A.G
1274/2-

Procedure
– Carefully pull engine cover panel off four retaining pins one
after the other -arrows-.

6. Checking fuel system for leaks 69

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Attach adapter - V.A.G 1274/2- with adapter - V.A.G 1274/1A-

to coolant system tester - V.A.G 1274 B- .
– Unscrew fuel supply line at high-pressure pump and connect
up hose of adapter - V.A.G 1274/2- in its place.

– If fitted, remove cover for suspension turret (right-side); to do

so, detach spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.

– Fit hose clamps - 3094- at the following points:

• Supply line upstream of fuel filter.
• Supply line to high-pressure pump.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Return line to fuelpermitted
tank. 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.

– Use cooling system tester - V.A.G 1274 B- to create a pressure

of between 1.0 ... 1.5 bar.
– If pressure drops constantly, locate leak and eliminate fault.

Note

By moving the hose clamps from the filter to the fuel tank con‐
nections it is also possible to check the fuel hoses at the same
time.

6.2 Checking fuel system for leaks (vehicles

with 8-cyl. 4.0 ltr. TDI engine)
A leaking fuel system can cause:
♦ Foam build-up or air bubbles in the supply line
♦ Lack of power, misfiring
♦ Starting problems

70 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

Special tools and workshop equipment required

♦ Hose clamps, up to 25 mm - 3094-

♦ Cooling system
permittedtester - V.A.G by 1274 B-AUDI
withAG adapter -
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised AUDI AG. does not guarantee or accept any liability
V.A.G 1274/1
withA- andto adapter
respect foroftesting
the correctness informationdiesel fuel - V.A.G
in this document. Copyright by AUDI AG.
1274/2-

Procedure
– Carefully pull engine cover panel off four retaining pins one
after the other -arrows-.

– Attach adapter - V.A.G 1274/2- with adapter - V.A.G 1274/1A-

to coolant system tester - V.A.G 1274 B- .
– Unscrew fuel return line at fuel rail and connect up hose of
adapter - V.A.G 1274/2- in its place.

6. Checking fuel system for leaks 71

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– If fitted, remove cover for suspension turret (right-side); to do

so, detach spreader clips -1- and unscrew bolted joint -2-.
– Pull cover out of retainers -arrows-.

– Fit hose clamps - 3094- at the following points:

• Supply line upstream of fuel filter.
• Return line to fuel tank.
• Return line from fuel cooler on engine.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Use cooling system tester - V.A.G 1274 B- to create a pressure
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.
of between 1.0 ... 1.5 bar.
– If pressure drops constantly, locate leak and eliminate fault.

Note

By moving the hose clamps from the filter to the fuel tank con‐
nections it is also possible to check the fuel hoses at the same
time.

6.3 Checking fuel system for leaks (vehicles

with 8-cyl. 4.2 ltr. TDI engine)
A leaking fuel system can cause:
♦ Foam build-up or air bubbles in the supply line
♦ Lack of power, misfiring
♦ Starting problems
Special tools and workshop equipment required

72 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

♦ Hose clamps, up to 25 mm - 3094-

♦ Cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/1 A- and adapter for testing diesel fuel - V.A.G
1274/2-

♦ Tandem pump tester - VAS 5187-

Procedure
– Carefully pull engine cover panel off four retaining pins one
after the other -arrows-.

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.

6. Checking fuel system for leaks 73

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Attach adapter - V.A.G 1274/2- with adapter - V.A.G 1274/1A-

to coolant system tester - V.A.G 1274 B- .
– Unscrew fuel supply line at high-pressure pump and in its
place connect up hose of adapter - V.A.G 1274/2- using banjo
bolt from -VAS 5187- to high-pressure pump.

– Fit hose clamps - 3094- at the following points:

• Supply line upstream of fuel filter.
• Supply line to high-pressure pump.
• Return line to fuel tank.

– Use cooling system tester - V.A.G 1274 B- to create a pressure

of between 1.0 ... 1.5 bar.
– If pressure drops constantly, locate leak and eliminate fault.

Note

By moving the hose clamps from the filter to the fuel tank con‐
nections it is also possible to check the fuel hoses at the same
time.

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.

74 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

7 Servicing accelerator mechanism

⇒ “7.1 Accelerator mechanism - exploded view of components”,
page 75
⇒ “7.2 Removing and installing accelerator pedal module with ac‐
celerator position sender”, page 76
⇒ “7.3 Checking kickdown switch F8 ”, page 76
⇒ “7.4 Removing and installing kickdown switch F8 ”, page 77

7.1 Accelerator mechanism - exploded view of components

1 - Accelerator pedal module

❑ With accelerator posi‐
tion sender - G79- and
accelerator position
sender 2 - G185-
❑ Removing and installing
⇒ page 76
2 - 10 Nm
3 - Electrical connector
4 - 10 Nm

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.

7. Servicing accelerator mechanism 75

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

7.2 Removing and installing accelerator

pedal module with accelerator position
sender
Removing
– Remove storage compartment on driver's side ⇒ Rep. gr. 68 .
– Unplug electrical connector -2-.
– Remove bolts -1- and -3-.
– Remove accelerator pedal module.
Installing
Installation is carried out in the reverse order; note the following:
– Install storage compartment on driver's side ⇒ Rep. gr. 68 .
Tightening torque
Component Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Accelerator pedal module to pedal bracket 10AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised by
with respect to the correctness of information in this document. Copyright by AUDI AG.

7.3 Checking kickdown switch - F8-

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
♦ Hand-held multimeter - V.A.G 1526 E-

♦ Auxiliary measuring set - V.A.G 1594 C-

Test conditions
• Vehicle diagnostic tester connected.
• No faults stored in fault memory.

76 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

• Engine stopped, ignition switched on

Test sequence
– Select the following menu items in Guided Functions mode
of vehicle diagnostic tester :
♦ 02-Gearbox electronics
♦ 02-Read measured values
– Select display group 8 (kickdown switch) from the list ⇒ Vehi‐
cle diagnostic tester.
• Accelerator
Protected not depressed:
by copyright. Copying displaypurposes,
for private or commercial remains
in partblank
or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
–withFully
respectdepress accelerator
to the correctness pedal
of information beyondCopyright
in this document. kickdown by AUDIpoint
AG. and
keep it pressed.
• Indicated on display: “kick-down”.
If display differs from specification described above:
– Use screwdriver to prise off cover caps.
– Unscrew bolts -arrows- and remove cover for kickdown switch.
– Unplug electrical connector.
– Connect hand-held multimeter - V.A.G 1526 E- to kickdown
switch - F8- to measure resistance.
• Specification: ∞ Ω (no continuity)
– Fully depress accelerator pedal beyond kickdown point and
keep it pressed.
• Specification: 0 Ω (continuity)
If display differs from specification described above:
– Renew kickdown switch - F8- ⇒ page 77 .

7.4 Removing and installing kickdown

switch - F8-
Removing
– Use screwdriver to prise off cover caps.
– Unscrew bolts -arrows- and remove cover for kickdown switch
- F8- .

7. Servicing accelerator mechanism 77

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Use a small screwdriver to release retainer tab -arrow- and

turn kickdown switch - F8- anti-clockwise.
– Unplug electrical connector.

Installing
Installation is carried out in the reverse order; note the following:
– Connect electrical connector -1- on kickdown switch - F8- .
– Insert kickdown switch in mounting on vehicle floor and en‐
gage by turning clockwise -arrow-. 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.

– Disengage cap -2- of kickdown switch -1-; to do so turn cap

anti-clockwise -arrow A-. Pull cap out as far as stop
-arrow B-.

– Press accelerator pedal down as far as stop -arrow- and re‐

lease again.

78 Rep. gr.20 - Fuel supply system

 Audi A8 2003 ➤
Fuel supply system, diesel engines - Edition 12.2013

– Pull cap -2- of kickdown switch -1- outwards by distance -a-

-arrow-.
• Distance -a- = 5 mm.

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.

– Lock cap -2- of kickdown switch -1- in its end position by turn‐
ing it 15° in clockwise direction -arrow-.
– Check kickdown switch - F8- ⇒ page 76 .

– Fit cover -arrows-.

7. Servicing accelerator mechanism 79