Audi Workshop Service and Repair Manuals

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

t  Wrench -T10202- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 1/3 full when removing the fuel delivery unit. Drain the tank if necessary. Procedure → Chapter.

–  Remove rear seat bench → Rep. gr.72. –  Unclip the retaining tabs -arrows- for the flange cover (right-side).

–  Unplug electrical connector -arrow- at flange.   WARNING t  The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection. t  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. t  Wear protective gloves. t  Wear safety goggles.

–  Disconnect fuel supply line -1- and fuel return line -2- by pressing release tabs. Vehicles with auxiliary heater: –  In addition, disconnect fuel supply line for auxiliary heater. Procedure → Rep. gr.82.

All vehicles (continued):   Caution The fuel tank must not be more than 1/3 full when removing the fuel delivery unit. Otherwise a large amount of fuel will escape. –  Unscrew locking ring using wrench -T10202-. –  Take flange (right-side) and seal of fuel delivery unit out of opening in fuel tank and move clear, leaving pipes connected.

–  In opening in fuel tank, press release tab to disconnect supply line -1- to suction-jet pump. –  Pull up retaining tab -arrow- and disengage fuel supply line -2- at fuel delivery unit. –  Remove fuel delivery unit.   Note t  When removing fuel delivery unit, make sure you do not bend float arm of fuel gauge sender -G-. t  Keep in mind that the fuel delivery unit still contains fuel. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following:   Note t  Take care not to bend the fuel gauge sender -G- when fitting the fuel delivery unit. t  Ensure that fuel hoses are securely seated. –  Insert fuel delivery unit into fuel tank, with flange set aside. –  Fit fuel supply line -2- onto fuel delivery unit so that it engages audibly. –  Fit supply line -1- leading to suction-jet pump so that it engages audibly.

–  Install new seal for flange (seal must be installed dry). –  Insert spring -2- into guide bore -arrow- and fit guide -1- (on flange) onto guide -3- on fuel delivery unit.   Note The fuel delivery unit is shown without fuel tank for illustration purposes.

–  Press flange down against spring pressure, and turn flange to installation position. l  Lug -2- on flange points towards arrow marking, and must be between tabs -1- and -3- on fuel tank.   Note The -arrow- points in direction of travel.

–  Tighten locking ring. –  Install rear seat bench → Rep. gr.72. –  Put at least 5 litres of fuel into tank after installing fuel delivery unit. Vehicles with auxiliary heater: –  Bleed fuel supply line leading to metering pump → Chapter.