Audi Workshop Service and Repair Manuals

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

t  Union nut tool -3217- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Drain the tank if necessary. Procedure → Chapter. Saloon: –  Detach trim in luggage compartment. –  If necessary, fold forward right backrest of rear seat bench. Avant: –  Remove left-side section of backrest (1/3 section) → Rep. Gr.72. –  Remove left-side trim in luggage compartment and anti-soiling tray → Rep. Gr.70.

All models: –  Unscrew cover for flange -arrows-.

–  Unplug electrical connector -arrow- at flange.

–  Mark fuel supply pipe -1- and fuel return pipe -2-.   WARNING t  The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Detach both pipes from flange (press release tabs). Vehicles with auxiliary heater: –  In addition, disconnect fuel line leading to metering pump for auxiliary heater (press release tab).

All models:   Caution 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. –  Use union nut tool -3217- to unscrew union nut. –  Pull fuel delivery unit just slightly out of opening in fuel tank and remove seal.

Vehicles with auxiliary heater from approx. 02.2003: –  Pull connection -2- upwards and disconnect suction pipe for auxiliary heater (press release tab).

All models: –  Move fuel delivery unit with flange slightly to one side with fuel delivery unit still located in fuel tank. –  Reach into fuel tank in the gap between flange and installation opening and release suction-jet pump -1-.   Note Fuel tank is shown in a cut-away view for illustration purposes.

–  Pull suction-jet pump -1- upwards with its supply pipe -2- connected. –  Disconnect supply pipe from suction-jet pump (press release tab). –  Remove suction-jet pump. –  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 Installation is carried out in the reverse order; note the following:   Note t  Renew seal. t  When inserting fuel delivery unit, make sure you do not bend float arm of fuel gauge sender -G-. t  Ensure that fuel hose is securely connected.

–  Insert fuel delivery unit in fuel tank. –  Attach supply pipe -2- to suction-jet pump connection -1-.

–  Clip suction-jet pump -1- onto fuel delivery unit. To do so, reach into gap between flange and opening in fuel tank. l  The suction-jet pump should click into place. –  Check that suction-jet pump has engaged properly.   Note Fuel tank is shown in a cut-away view for illustration purposes.

Vehicles with auxiliary heater from approx. 02.2003: –  Attach suction pipe for auxiliary heater to connection -2-.

All models: –  Install new seal for flange (seal must be installed dry). –  Press flange down against spring pressure, and turn flange to installation position. l  Arrow -2- on flange must align with arrow -1- on fuel tank.

–  Tighten union nut for flange.

–  Install fuel supply pipe -1- and fuel return pipe -2- (as marked). –  Plug in electrical connector. –  Put at least 5 litres of fuel into tank after installing fuel delivery unit. Vehicles with auxiliary heater: –  Let auxiliary heater run with full load for 10 minutes to bleed fuel supply pipe going to metering pump. Tightening torque

Component	Nm
Union nut for fuel delivery unit	80