Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSAUDI1996A4 BASE, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)EXTERNAL PAGESDIFFERENT CARSECTION 59 (FUEL SUPPLY SYSTEM - ALL ENGINES)
1996 Audi A4 Base, Standard
Section 59 (Fuel Supply System - All Engines)
1996 Audi A4 Base, StandardSECTION Section 59 (Fuel Supply System - All Engines)
WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2005 Audi allroad, 2004 Audi allroad, 2004 Audi A6, 2003 Audi allroad, and 2003 Audi S6. However, it is still accessible from the selected car via links, so may be relevant.
- Fuel supply system components, removing and installing
- Fuel supply, Front Wheel Drive (FWD)
- Notes
- Fuel tank with sub components, component overview
- Fuel tank, draining
- Fuel tank with attachments, removing and installing
- Fuel pump module including sender for fuel gauge, component overview
- Fuel pump, checking electrically
- Fuel pump delivery rate, checking
- Fuel pump module, removing and installing
- Sender for fuel gauge-G-, checking - front wheel drive (FWD)
- Sender for fuel gauge-G, removing and installing
- Fuel supply, All Wheel Drive (AWD)
- Notes
- Fuel tank with attachments, component overview - vehicles with 6-cylinder engine and A6 Allroad
- Fuel tank, draining
- Fuel tank with attachments, removing and installing - vehicles with 6-cylinder engine and A6 Allroad
- Fuel filler neck with expansion tank, component overview - vehicles with 6-cylinder engine and A6 Allroad
- Fuel filler neck with expansion tank, removing and installing - vehicles with 6-cylinder engine and A6 Allroad
- Fuel tank with attachments, component overview - vehicles with 8-cylinder engine except A6 Allroad
- Fuel tank with attachments, removing and installing - vehicles with 8-cylinder engine except A6 allroad
- Fuel filler neck with expansion tank, component overview - vehicles with 8-cylinder engine except A6 Allroad
- Fuel filler neck with expansion tank, removing and installing - vehicles with 8-cylinder engine except A6 Allroad
- Seal insert for gas station fuel nozzle, removing and installing - all engines
- Fuel pump module with sender for fuel gauge, component overview - all engines
- Fuel pump, checking electrically
- Fuel pump delivery volume, checking - vehicles with 6-cylinder naturally aspirated engine
- Fuel pump delivery volume, checking - vehicles with 6-cylinder turbo engine
- Fuel pump delivery volume, checking - vehicles with 8-cylinder engine (with toothed belts)
- Fuel pump delivery volume, checking - vehicles with 8-cylinder engine (open loop system)
- Fuel sender with fuel pump, removing and installing
- Fuel transfer system - Vehicles with 8 - cylinder engine
- Function
- Component overview, Transfer Fuel Pump (FP) -G23-
- Fuel Pump (FP) -G6-, checking
- Transfer Fuel Pump (FP) -G23-, checking
- Fuel Pump (FP) Control Module -J538-, checking
- Special tools, testers and auxiliary items
- Test conditions:
- Test sequence
- Voltage supply, checking
- Activation by ECM, checking
- Diagnosis circuit, checking
- Voltage supply for Fuel Pump (FP) -G6- (of the Fuel Pump (FP) Control Module -J538-), checking
- Voltage supply for fuel pump -G23 (from fuel pump control module -J538), checking
- Tightening torque
- Fuel pump delivery rate, checking
- Fuel pump (FP) -G6-, removing and installing
- Transfer fuel pump (FP) -G23-, removing and installing
- Sender for Fuel gauge - All Wheel drive
- Suction jet pump-all wheel drive (AWD)
- Function
- Suction jet pump with distributor connector, checking - vehicles with 6-cylinder naturally aspirated engine
- Suction jet pump with distributor connector, checking - vehicles with 6-cylinder turbo engine
- Suction jet pump with distributor connector, checking - vehicles with 8-cylinder engine (with toothed belts)
- Suction jet pump with manifold test -vehicles with 8-Cylinder-naturally aspirated engine (with open-loop system)
- Suction jet pump with manifold test - vehicles with 8-cylinder-Turbo engine
- Suction jet pump with distributor connector, removing and installing
- Fuel filter - component overview
- EVAP canister/tank leak diagnostic system, servicing - FWD & AWD
- Notes
- Emission Evaporative (EVAP) canister, removing and installing
- EVAP canister/tank leak diagnostic system, diagram - 6-cylinder naturally aspirated engine
- EVAP canister/tank leak diagnostic system, diagram - 6-cylinder turbo engine
- EVAP canister/tank leak diagnostic system, diagram - 8-cylinder naturally aspirated engine
- EVAP canister/tank leak diagnostic system, diagram - 8-cylinder Turbo engine
- Fuel tank, leak diagnostic system
- Automatic Evaporative Emission (EVAP) system, diagnostic leak test
- Diagnostic leak test, performing
- Evaporative Emissions (EVAP) System Diagnosis using KLI9210 EVAP Tester
- Tank leak diagnostic, performing
- Leak Detection Pump (LDP) -V144-, checking
- Special tools and equipment
- Test sequence:
- Test procedure
- Internal resistance test
- Voltage supply test
- Output circuit checking - Vehicles with mechanical accelerator operation
- Input circuit checking - Vehicles with mechanical accelerator operation
- Output circuit checking - Vehicles with electronic engine power control (drive-by wire)
- Input circuit checking - Vehicles with electronic engine power control (drive-by wire)
- Leak Detection Pump (LDP) -V144-, removing and installing
- Accelerator Pedal (AP) cable, servicing - vehicles with mechanical accelerator mechanism
- Accelerator Pedal (AP), servicing - vehicles with Electronic Power Control (EPC) (drive by wire)
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.