Audi Workshop Service and Repair Manuals

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

t  Special wrench -T10202-

t  Fuel pump spanner -3307- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 1/4 full when removing the fuel delivery unit. Drain the tank if necessary. Procedure → Chapter.

–  Remove rear seat bench → Rep. Gr.72. –  Unscrew cover for flange (right-side) -arrows-.

–  Unplug electrical connector -arrow- at flange (right side of vehicle).   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.

–  Disconnect fuel line -arrow- from flange (right side of vehicle) by pressing release tab. Vehicles with auxiliary heater: –  In addition, disconnect fuel line leading to metering pump for auxiliary heater by pressing release tab.

All models:   Caution The fuel tank must not be more than 1/4 full when opening the flange. Otherwise a large amount of fuel will escape. –  Unscrew locking ring using wrench -T10202-.

–  Detach flange with seal from fuel tank opening. –  Unplug electrical connector -arrow- on inside of flange.

–  Carefully pull flange (together with fuel hose -2- coming from fuel pump) out of fuel tank until Y-connector is visible. –  Press release tabs -arrows- and disconnect fuel hose at Y-connector. –  Reach into fuel tank opening and disconnect fuel hose -1- from fuel delivery unit.   Note

Fuel tank is shown in a cut-away view for illustration purposes. –  Insert fuel pump spanner -3307- through fuel tank opening and apply at fuel delivery unit.

–  Release fuel delivery unit by turning to stop (approx 15°) in anti-clockwise direction (bayonet connection) using fuel pump spanner -3307-. l  Notch -1- will then be aligned with marking -2-. –  Remove fuel delivery unit.   Note 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  Ensure that fuel hoses are securely seated.

–  Fit fuel delivery unit into baffle housing (in tank) so that notch -1- on fuel delivery unit is aligned with marking -2- on baffle housing. l  The fuel delivery unit should move down noticeably.

–  Insert fuel pump spanner -3307- through fuel tank opening and apply at fuel delivery unit.

–  Secure fuel delivery unit by turning to stop (approx 15°) in clockwise direction (bayonet connection) using fuel pump spanner -3307-. l  Notch -1- will then be aligned with marking -3-.

–  Reach into fuel tank opening and insert fuel hose -1- into appropriate hole on fuel delivery unit. –  Connect fuel hose -2- to Y-connector.

–  Attach electrical connector -arrow- to inside of flange.

–  Install new seal for flange (seal must be installed dry). –  Move flange to installation position. l  Lug -2- on flange must be between tabs -1- and -3- on fuel tank.   Note The -arrow- points in direction of travel.

–  Tighten locking ring. –  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
Locking ring for fuel delivery unit	145