Audi Workshop Service and Repair Manuals

Observe notes .

Observe safety precautions=> Page 20-2

Observe rules for cleanliness => Page 20-3

Special tools, testers and auxiliary items

• ◆ Ring nut spanner 3217
• ◆ Fuel pump spanner 3307
• ◆ Hose clamp pliers V.A.G 1275
• ◆ Fuel extractor V.A.G 1433 A

Removing

Notes:

• ◆ The fuel tank must not be more than 1/3 full.
• ◆ If necessary, drain tank using fuel extractor V.A.G 1433 A.

• ‒ Obtain radio code on vehicles with coded radio.
• ‒ With ignition switched off,disconnect battery earth strap.

• ‒ Detach trim in luggage compartment.
• ‒ Unbolt cover for flange on fuel tank under floor trim in luggage compartment.
• ‒ → Mark the supply pipe -2- and return pipe -3-, then pull pipes off flange.
• ‒ Release 4-pin connector -1- and unplug.

• ‒ → Remove union nut with spanner 3217.
• ‒ Remove flange and seal out of opening in fuel tank.
• ‒ Unplug connector for fuel gauge sender on inside of flange.
• ‒ Pull fuel return pipe off inside of fuel delivery unit flange (press release tabs).

• ‒ → Insert fuel pump spanner 3307 through opening in fuel tank and apply spanner to inner section of baffle housing.
• ‒ Using spanner 3307 turn inner section of baffle housing anti-clockwise as far as it will go (approx. 15°), and take out fuel pump with inner section of baffle housing.

Pre-assembling flange and inner section of baffle housing

• ‒ If flange has been separated from fuel delivery unit, pre-assemble components before installing.

• ‒ → Angle between flange and inner section of baffle housing: 10°
• Compress clamps for supply pipe (between pump and flange) using hose clamp pliers V.A.G 1275.
• Connect electrical wires onto fuel pump
  (M4: 1.5 Nm; M5: 2 Nm)

Note:

Fit a toothed washer under each nut.

• ‒ Secure the electrical wires using a fuel-resistant cable tie.

Installing

• ‒ Insert inner section of baffle housing, supply pipe and flange in fuel tank.
• ‒ → Fit inner section of baffle housing into outer section of baffle housing (in tank) so that notch -1- on inner section of housing is aligned with marking -2- on outer section of housing.
• ‒ The inner section of baffle housing should move down noticeably.

Note:

Baffle housing is shown without fuel tank for a clearer illustration.

• ‒ → Apply fuel pump spanner 3307 and turn pump together with inner section of baffle housing clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting)=>Fig.A20-0112.

• ‒ → When installing, turn flange in a clockwise direction, as indicated in illustration.
• ‒ Connect return pipe on inside of flange.

Note:

Lubricate O-rings with fuel or other lubricant.

• ‒ Wrap fuel gauge sender wire once around the return pipe (in fuel tank) and connect at flange.

Note:

Lubricate the flange seal with fuel before fitting.

• ‒ → Insert flange in fuel tank; note correct installation position:
• ‒ Marking onflange must coincide with marking on fuel tank
  -arrows-.
• ‒ Installation position for vehicles with four-wheel drive:
  -arrow 1- must be aligned with -arrow 2-.

Note:

-Arrow 3- is for vehicles with front-wheel drive (can be disregarded).

• ‒ → Tighten union nut with spanner 3217.
• ‒ Connect pipes and plug in the connector.

Note:

Ensure that fuel pipes are securely seated.

Tightening torque