Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Ring nut spanner 3217
• ◆ Fuel pump spanner 3307
• ◆ Hose clamp pliers V.A.G 1275

Note:

The illustration shows the correct routing of hoses inside the tank.

• Baffle housing
• Fuel return hose
• ◆ From suction jet pump
• Flange
• Suction jet pump
• Fuel hose
• ◆ From fuel pump to suction jet pump
• Fuel supply hose

Observe safety precautions.

Observe rules for cleanliness => Page 20-3.

Removing

• ‒ The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Drain fuel tank if necessary.
  Procedure => Page 20-107.
• ‒ Detach floor trim in luggage compartment.
• ‒ Unbolt cover for flange.
• ‒ → Disconnect fuel return pipe -2- and fuel supply pipe -3- from flange.
• ‒ Release and unplug connector -1-.

• ‒ → Remove union nut with spanner 3217.
• ‒ Remove flange and seal out of opening in fuel tank.

• ‒ → Pull fuel return hose -2- off inside of flange -1- (use uncoupling tool T40020 or press release tabs).
• ‒ Unplug connector for fuel gauge sender on inside of flange.

• ‒ → Disconnect fuel hose -2- from fuel pump at connection -1- for suction jet pump (use uncoupling tool T40020 or press release tabs).

• ‒ → Press retaining tab, and at the same time pull the sender unit out of baffle housing in fuel tank -arrows-.

• ‒ → Insert fuel pump spanner 3307 through opening in fuel tank and apply spanner to fuel delivery unit.
• ‒ Using spanner 3307, turn fuel delivery unit anti-clockwise as far as it will go (approx. 15°), and take out fuel delivery unit.

Installing

Install in reverse sequence; note the following points:

Note:

Secure all hose connections with the correct hose clips (same as original equipment)

=> Parts catalogue

• ‒ Place fuel delivery unit in fuel tank.

• ‒ → Fit fuel delivery unit into outer section of baffle housing (in tank) so that notch -1- on fuel delivery unit is aligned with marking -2- on outer section of housing.
• ‒ The fuel delivery unit should move down noticeably.
• ‒ Apply fuel pump spanner 3307 and turn fuel delivery unit clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting).

• ‒ Insert fuel gauge sender into guide on outer section of baffle housing and press down until it clicks into place.

Notes:

• ◆ Use new O-rings.
• ◆ Ensure that O-rings are not trapped - use lubricant if necessary.

• ‒ → Connect fuel hose -2- (from fuel pump) to connection -1- for suction jet pump.
• ‒ Wrap fuel gauge sender wire once around the supply hose (in fuel tank) and connect at flange.

• ‒ → Connect return hose -2- to inside of flange -1-.
• ‒ Fit new sealing ring for flange in fuel tank opening (sealing ring should be dry).

• ‒ → Fit flange into fuel tank; note correct installation position:
• ‒ Installation position for vehicles with four-wheel drive:
  -arrow 1- must be aligned with -arrow 2-.

Note:

-Arrow 3- is for vehicles with front-wheel drive (can be disregarded).

• ‒ → Tighten union nut with spanner 3217 (60 Nm).
• ‒ Connect pipes and plug in the connector.