Audi Workshop Service and Repair Manuals

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

t  Union nut tool -T40068 A- Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness → Chapter.   WARNING Large amounts of fuel can escape. The fuel tank must not be more than 1/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. –  Drain fuel tank if necessary → Chapter. –  Move passenger's seat as far to front as possible (if necessary).

–  Remove rear seat bench → Rep. gr.72. –  Unscrew cover for flange -arrows-.

–  Unplug electrical connector -1- on flange. Vehicles with auxiliary heater: –  Disengage electrical connector -2- for metering pump for auxiliary heater on flange and move clear.

All vehicles (continued):   WARNING The fuel can become extremely hot. This can cause injuries. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. 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. –  Press release tabs and disconnect fuel lines -2- and -3- on flange. Vehicles with auxiliary heater: –  Press release tab and disconnect fuel line -1- leading to metering pump for auxiliary heater at flange.

All vehicles (continued):   WARNING Large amounts of fuel can escape. The fuel tank must not be more than 1/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. –  Unscrew union nut using union nut tool -T40068 A--arrow-.   Note The plastic detent on the threaded ring will break off when the union nut is unscrewed - this can be disregarded.

–  Take flange -2- out of fuel tank and detach seal -1-.

WARNING Safety risk from escaping fuel: the fuel delivery unit is still filled. Use a cloth to catch escaping fuel. –  Swivel fuel delivery unit -1- to left side of vehicle -arrow- and tilt slightly out of fuel tank.   Note When removing fuel delivery unit, make sure you do not bend float arm of fuel gauge sender -G-. –  Pull fuel gauge sender -G--item 2- out of opening in fuel tank and remove fuel delivery unit with suction pipe from fuel tank. Installing Installation is carried out in the reverse order; note the following: l  Tightening torque → Chapter „Fuel delivery unit and fuel gauge sender - exploded view“   Note t  Renew seal and union nut. t  Take care not to bend float arm of fuel gauge sender -G- when fitting fuel delivery unit. t  Ensure that fuel hoses are securely seated.

–  Pivot suction pipe -3- on fuel delivery unit -2- downwards -arrow A-. –  First guide suction pipe into fuel tank -arrow B-. –  Then insert float -1- on fuel gauge sender -G- into fuel tank.

–  Swivel fuel delivery unit -1- to left side of vehicle and guide into fuel tank -arrow- (make sure fuel gauge sender -2- is not damaged).

–  Slip new seal -1- onto flange -2- and insert in groove on fuel tank.

–  Slip union nut -1- over your left arm and press flange -2- firmly into installation position -arrow- with your left hand. l  Lug -4- on flange must be between tabs -3- and -5- on threaded ring.

–  Take union nut -1- off your left arm with your right hand and at the same time keep pressing down flange -2- firmly with your left hand -arrow-. –  Position union nut -1- with your right hand in such a way that double ridge -5- on ribs aligns with lug -3- of flange (approx. „ten o'clock position“). This will make union nut engage immediately with beginning of thread -4- when tightening.

–  Keep pressing flange downwards firmly -arrow-. –  Turn union nut approx. 480° with your right hand until double ridge -1- is in approx. „two o'clock position“ and at the same time keep on pressing flange downwards firmly with your left hand.

Caution Take care to avoid leakage at flange. Press flange downwards firmly when tightening union nut to make sure flange does not also turn. –  Tighten union nut for flange using union nut tool -T40068 A-.

l  Checking: Double ridge -1- must now be aligned between „seven o'clock and eight o'clock position“.

–  Connect fuel lines -1, 2, 3-. –  Connect electrical connectors. –  Install cover for flange → Fig.. –  Install rear seat bench → Rep. gr.72. –  Put at least 5 litres of fuel into tank after installing fuel delivery unit. Vehicles with auxiliary heater: –  Bleed fuel supply line leading to metering pump → Chapter.