Campaign - Fuel Line Repacement: Overview
August 1999Subject: 2000 Model Year Audi TT Vehicles
Replace Fuel Line
Work Procedure
- Remove fuse # 28 from relay panel (left row, fifth large fuse from the top) on left side of instrument panel
- Start and run engine until engine runs out of fuel (relieves pressure in fuel system)
- Switch ignition OFF
- Record radio preset stations
- Open hood and disconnect battery ground (GND) strap
- Remove cover -1- above engine coolant bottle on right side of engine compartment
WARNING:
- FIRE HAZARD.
- DO NOT SMOKE, WORK NEAR HEATERS OR HAVE ANYTHING IN THE AREA THAT COULD IGNITE THE FUEL OR FUMES.
- Disconnect the fuel pressure line -2-, fuel return line -3-, canister purge line -4- and vacuum line - 5- by pressing tab on connectors
NOTE:
Record position and color of all lines and connectors
- Remove cover of line holder -6- and unsnap lines from line holder
- Lift vehicle on hoist
- Remove 6 nuts -7- holding rear cover panel and pull cover off pins -8-
- Disconnect the black fuel pressure line -2-, blue fuel return line -3-, white canister purge line -4- and black vacuum line -5- by pressing tab on connectors
- Unsnap three line retaining clips -9- from the vehicle
- Carefully remove the foam seal -10- around the lines and pull the lines out of the vehicle
- Using old line assembly as a guide, insert new vacuum line 8N0 201 935D into clips of new set of fuel lines 8N0 200 059B. DO NOT remove the covers from the end of the lines
HINT: Loosely taping the lines together on end caps will aid the installation
- Insert fuel lines into slot of floor pan and set length position of lines
- Lower vehicle on hoist
- In the engine compartment, remove protective caps on ends of lines, snap lines into line holder and reinstall cover
- Reconnect the fuel pressure line -2- to black line, fuel return line -3- to blue line, canister purge line -4- to white line and vacuum line -5- to black line with white nipple
- Raise vehicle on hoist
- Reinstall foam seal around lines and into slot
- Snap three line retaining clips -9- to the vehicle
- Connect the black fuel pressure lines -2-, blue fuel return lines -3-, white canister purge lines -4- and black vacuum lines -5-
- Lower vehicle on hoist
WARNING:
Ensure that there is no person inside the vehicle when connecting battery ground cable.
- Reinstall fuse # 28 in fuse panel and reconnect battery (GND) cable
- Start engine and check for fuel leaks
- Connect VAG 1551 and check for stored DTCs
- Clear DTC memory if DTCs were found
- Set readiness code
- Reset clock, radio preset stations and power windows
- Reinstall cover -1- above engine coolant bottle on right side of engine compartment
- Raise vehicle on hoist
- Reinstall cover panel with clips -8- and secure using 6 new nuts -7-, part number N 902 867 03
- Lower vehicle on hoist
- Close hood
- Properly dispose of all removed parts
Parts Disposal
All removed fuel lines and connecting parts must be immediately disposed of in accordance with federal, state and/or local disposal requirements.
Replacement Time/Reimbursement
To ensure prompt and proper payment, be sure to enter the code below. Recall claims will only be paid for vehicles which show the KV code in the OTIS campaign inquiry system on the day of repair.
Recall Verification
For verification, always check your OTIS recall inquiry system. The OTIS system is the only campaign verification system; other systems are not valid.
Dealer Obligation
To ensure satisfaction as well as minimize inconvenience to your customers, you are urged to contact each customer by telephone on August 19, 1999 to arrange for a service appointment, then to service each vehicle at the scheduled service appointment time, offer and supply a loaner vehicle for the day, if necessary, and make sure that each vehicle is returned to the customer washed and cleaned inside and the full tank filled.
Do not let any customer wait longer than necessary during the recall service of the vehicle. Every effort should be made to reduce inconvenience to customers.