Audi Workshop Service and Repair Manuals

Removing and installing fuel delivery unit Special tools and workshop equipment required

t  Union nut tool -3217-

t  Removal wedge -3409- Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness → Chapter.   WARNING Large amounts of fuel can escape. The fuel tank must not be more than 3/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. –  Drain fuel tank if necessary → Chapter. –  Move front right seat all the way forwards.

–  Remove rear seat bench → Rep. gr.72. –  Unclip cover -1- for fuel tank flange at retainers -arrows- using removal wedge -3409-.

–  Release retainer catch and unplug electrical connector -1- on flange.   WARNING The fuel can become extremely hot. This can cause injuries. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. Risk of injury - fuel system operates under high pressure. To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection.

–  Disconnect fuel lines -1- and -2- on flange (press release tab).

WARNING Large amounts of fuel can escape. The fuel tank must not be more than 3/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. –  Unscrew union nut using union nut tool -3217-.

–  Pull flange out of opening in fuel tank. –  Take seal out of opening in fuel tank.   WARNING Safety risk from escaping fuel: the fuel delivery unit is still filled. Use a cloth to catch escaping fuel. –  Carefully pull fuel delivery unit -1- with fuel gauge sender out through opening in fuel tank.   Note When removing fuel delivery unit, make sure you do not bend float arm of fuel gauge sender -G-. Installing l  Tightening torque → Chapter „Fuel delivery unit and fuel gauge sender - exploded view“ Remaining installation steps are carried out in reverse sequence; note the following:   Note t  Renew seal. t  Take care not to bend float arm of fuel gauge sender -G- when fitting fuel delivery unit. –  Carefully guide fuel delivery unit -1- with fuel gauge sender in through opening in fuel tank.

–  Install new seal for flange (seal must be installed dry).   Caution Leakage risk The seal must not be pinched or damaged when installing the flange. –  Press flange down against spring pressure and turn flange to installation position. l  Lug -2- on flange must align with arrow -1- on fuel tank. –  Connect fuel lines so they engage audibly. –  Plug in electrical connector and make sure it is correctly engaged. –  Install rear seat bench → Rep. gr.72. –  Put at least 5 litres of fuel into tank after installing fuel delivery unit.