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

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

–  Unplug electrical connector -arrow- at flange.

–  Mark fuel supply line -1- and fuel return line -2-.   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. –  Detach both pipes from flange (press release tabs). Vehicles with auxiliary heater: –  In addition, disconnect fuel supply pipe 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 pipe -2- to suction-jet pump. –  Disconnect fuel supply pipe -1- (press release catch -arrow-). –  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  Renew seal. 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 pipe -1-, so that it engages (you should hear it click into place). –  Fit supply pipe -2- leading to suction-jet pump so that it engages audibly. –  Install new seal for flange (seal must be installed dry). –  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  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. –  Connect battery. Observe notes on procedures required after connecting battery → Rep. gr.27. Vehicles with FSI engine: –  After renewing the fuel delivery unit, the fuel pump must be adapted → Chapter.