Audi Workshop Service and Repair Manuals

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

t  Union nut tool -3217- t  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.   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 1/3 full when removing the fuel delivery unit. Otherwise a large amount of fuel will escape. –  Unscrew union nut using union nut tool -3217-. –  Take flange of fuel delivery unit out of opening in fuel tank and move clear, leaving hoses connected.

–  Reach into fuel tank and disconnect connector -1-. –  Press release tab for hose connector and disconnect hose -2-. –  Lift retainer -3- upwards and disengage retainer and hose -4- from fuel delivery unit -5-.   Note The fuel delivery unit has been removed in the illustration. –  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 the seal. t  When installing fuel delivery unit, take care not to bend float arm of fuel gauge sender -G-. t  Make sure that fuel hoses are securely fitted.

–  Insert fuel delivery unit -5- into fuel tank, with flange set aside. –  Insert retainer -3- for hose -4- in fuel delivery unit and press in until it engages. l  The retainer must engage properly. –  Press hose connector onto hose -2- so that it engages. –  Plug in electrical connector -1- for fuel gauge sender 2 -G169-. –  Slot guide sleeve on flange into guide sleeve on fuel delivery unit; make sure spring is not damaged.

–  Press flange down against spring pressure, and turn flange to installation position. l  Marking on flange must align with marking on fuel tank -arrows-.

–  Tighten union nut using union nut tool -3217-.

–  Connect fuel pipes: t  Fit black fuel supply pipe -1- onto connection marked -V-. t  Fit blue fuel return pipe -2- onto connection marked -R-. –  Plug in electrical connector. –  Connect battery and perform steps required after re-connecting battery → Rep. Gr.27. –  Put at least 5 litres of fuel into tank after installing fuel delivery unit.