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 1/4 full when removing the fuel delivery unit. Drain the tank if necessary. Procedure → Chapter.

Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Slide cover above battery to the right -arrow 1- and lift off -arrow 2-.

–  With ignition switched off, disconnect earth strap -arrow- at battery.

Audi RS4: –  Lift luggage compartment floor mat and make sure it remains in position. –  With ignition switched off, disconnect earth strap -arrow- at battery. All models: –  Briefly open filler cap for fuel tank and close again.

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

Audi RS4: –  Move electrical connector -arrow- for fuel pump control unit -J538- clear and detach connector.

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

–  Mark fuel return pipe -1- and fuel supply pipe -2-.   WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. –  Detach both pipes from flange (press release tabs). –  On vehicles with auxiliary heater, also disconnect fuel line leading to metering pump for auxiliary heater (press release tab).

WARNING 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-. –  Take flange and seal out of opening in fuel tank and move flange clear, leaving pipes connected.

–  Disconnect supply pipe -1- for suction-jet pump by pressing release tab. –  Disengage fuel supply pipe -2-. –  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  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. –  Engage fuel supply pipe -2-. –  Fit supply pipe -1- leading to suction-jet pump so that it engages audibly.

Make sure fuel hoses are properly routed. t  The fuel supply pipe -1- must be routed between the guide tube -4- and the connecting piece -2- for fuel return pipe. Also make sure that it is routed around outside of guide tube -3-. –  Insert guide tubes -3- and -4- on flange into corresponding holes -arrows- in fuel delivery unit.   Note The fuel delivery unit is shown without the fuel tank for illustration purposes.

–  Install new seal for flange (seal must be installed dry). –  Press flange down against spring pressure, and turn flange to installation position. l  Lug -2- on flange must be between tabs -1- and -3- on fuel tank.

–  Tighten locking ring. –  Connect battery. Observe notes on procedures required after connecting battery → Rep. Gr.27. –  Put at least 5 litres of fuel into tank after installing fuel delivery unit. –  On vehicles with 4-cylinder TFSI engine the fuel pump should be adapted after renewing the fuel delivery unit → Chapter. Tightening torque

Component	Nm
Locking ring for fuel delivery unit	145