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.   Caution To prevent damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect battery → Rep. Gr.27.

–  Unbolt cover (right-side) underneath rear seat bench. –  Unplug electrical connector -arrow-.   WARNING 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.

–  Press release tabs and disconnect fuel supply pipe -1- and fuel return pipe -2-.

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. –  Unscrew union nut using union nut tool -3217-. –  Pull fuel delivery unit and seal out of opening in fuel tank.   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  Renew seal. t  Take care not to bend the fuel gauge sender when fitting fuel delivery unit.

–  Fit new seal for flange in fuel tank opening (seal should be dry). –  Tighten union nut using union nut tool -3217-.

–  Observe correct installation position: l  Marking on flange must align with marking on fuel tank -arrows-. –  Connect fuel pipes. l  Fit blue fuel return pipe -1- onto connection marked -R-. l  Fit black fuel supply pipe -2- onto connection marked -V-. –  Connect battery. Observe notes on procedures required after connecting battery → Rep. Gr.27.