Audi Workshop Service and Repair Manuals

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

t  Special wrench -T10202- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Drain the tank if necessary. Procedure → Chapter. Saloon: –  Detach trim in luggage compartment. –  If necessary, fold forward right backrest of rear seat bench. Avant: –  Remove left-side section of backrest (1/3 section) → Rep. Gr.72. –  Remove left-side trim in luggage compartment and anti-soiling tray → Rep. Gr.70.

All models: –  Unscrew cover for flange in luggage compartment -arrows-.

–  Unplug electrical connector -arrow- at flange.

–  Mark fuel supply pipe -1- and fuel return pipe -3-.   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). Vehicles with auxiliary heater: –  In addition, disconnect fuel line -2- leading to metering pump for auxiliary heater (press release tab).

All models:   Caution The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Otherwise a large amount of fuel will escape. –  Unscrew locking ring using wrench -T10202-.

–  Pull fuel delivery unit just slightly out of opening in fuel tank and remove seal. –  Move flange slightly to one side with fuel delivery unit still located in fuel tank. –  On vehicles with auxiliary heater, pull suction pipe -2- for auxiliary heater out of fuel tank and disconnect (press release tab). –  Disconnect supply pipe -1- for suction-jet pump on underside of flange by pressing release tab. –  Release suction-jet pump -arrows- and remove. –  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  When inserting fuel delivery unit, make sure you do not bend float arm of fuel gauge sender -G-. t  Ensure that fuel hose is securely connected.

–  Insert fuel delivery unit in fuel tank. –  Clip suction-jet pump onto fuel delivery unit. To do so, reach into gap between flange and opening in fuel tank. l  The suction-jet pump should click into place. –  Check that suction-jet pump has engaged properly. –  Fit supply pipe -1- leading to suction-jet pump on underside of flange so that it engages audibly. –  On vehicles with auxiliary heater, fit suction pipe -2- going to auxiliary heater so that it engages audibly.

–  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.   Note The -arrow- points in direction of travel.

–  Tighten locking ring.

–  Install fuel supply pipe -1- and fuel return pipe -3- (as marked). –  On vehicles with auxiliary heater, install fuel line -2- leading to metering pump for auxiliary heater. –  Plug in electrical connector. –  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