Service

The following components must be replaced and repaired per the instructions in this TSB.

1. Start by obtaining repair kit 4F0 298 200 B (includes 1X wires for suction jet pump, 1X adapter cable, 6x connectors).

2. Remove the electric fuel pump with fuel level sender G.





3. Cut the electric cables of the connector to and from sender G directly behind the plug (Figures 1 and 2).

4. Connect the two blue wires with the connector as described below.





a. Ensure wire protrudes by 5 mm.





b. Place the wire on the slit.





c. Press the flap onto the wire.





d. Press the flap to the stop with pliers.








e. Repeat the process for the second blue wire.

5. Connect the two black wires with the connector following the procedure in Step 4.





6. Make sure that the cable is routed below the fuel pipes. Use a cable tie to attach the fuel pump cable (which is yellow and black) and the cable of sender G (which is blue and black) below the arch of the supply pipe (Figure 9).

Note:
On S6 vehicles the electric cables of the sender must be attached without the yellow and black cable of the fuel pump directly behind the 90° connector of the supply pipe - no illustration.





7. Close the cable tie firmly, so that the electric wires are very difficult to move. Be careful not to squash the supply pipe. Ensure the electric wires are not under tension.

Note:
Make sure that no electric wires interfere with the swivel range of the sender G. Vehicle could run out of fuel if wires interfere with the function of sender G.





8. Cut the electric cables directly behind the plug to sender G169 (Figure 11).





9. Trim the insulated ends of the adapter cable in the kit by about 1 mm after the start of the insulation cutoff (Figure 12).





10. Connect the adapter cable with the binders (black to black and blue to blue). Perform the connection from the side of the tank unit.

Route the cables above the yellow cable (Figure 13, arrow) on the opposite side to the unsprung guide pins.





Make sure that the cable is routed below the fuel discharge pipe (Figure 14).





11. Form a loop after the plug to sender G169 (Figure 15).





12. With a cable tie, attach the plug and the two electric cables on the pipe to the suction jet pump, directly after the connector (Figure 16).





13. Make sure that the two electric cables cross the pipe so that the cable does not slip (Figure 17).





14. Tie the electric cables (yellow and black cables of the fuel pump and blue and black cables of sender (G) together with a cable binder (Figure 18).

15. Remove sender G169 together with the suction jet pump booster.





16. Cut the electric cables directly behind the connector (Figure 19).

17. Repeat steps 4 and 5.








18. Position the wiring from the suction jet pump to sender G 169 according to Figures 20-22.

19. Install suction jet pump with Sender G 169 and fuel pump with Sender G per repair manual.

20. Check the female connector of the body side harness with a Pin Drag" test to ensure the connection to the vehicle wiring harness is correct.

21. If both DTC 00771 and DTC 00438 were stored, check the ground wire at pin 3 of the T5a connector of the body harness. The voltage drop should be less than .4 volts.

22. Clear the fault memory in the instrument cluster.

23. Recheck for proper operation.