Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, Removing And Installing







- Wrench T10202

Removing
Observe safety precautions.
Observe rules for cleanliness.

CAUTION:
- To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 1/4. Drain fuel tank if necessary.
- Observe procedures for disconnecting battery.

All except Audi RS4:







- Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 - .







- With ignition switched off, disconnect Battery Ground (GND) strap - arrow - .

Audi RS4:
- Raise luggage compartment floor covering and secure.







- With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

All:
- Open fuel filler flap briefly and then close again.
- Remove rear seat bench.







- Unbolt cover for right locking flange - arrows - .

Audi RS4:







- Free up electrical connector - arrow - for Fuel Pump (FP) Control Module J538 and disconnect.

All:







- Disconnect electrical harness connector - arrow - at right locking flange.







- Mark fuel return line - 1 - and fuel supply line - 2 - .

CAUTION: The fuel system is under pressure. Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

- Pull both lines from locking flange, by pressing release buttons.

CAUTION: Locking flange may only be opened when fuel tank is maximum 1 / 4 full. Otherwise, a large amount of fuel will spill out.







- Remove locking ring using wrench T10202 .
- Remove locking flange and seal from opening in fuel tank and lay aside locking flange with lines still connected.







- Disconnect suction jet pipe - 1 - to suction jet pump by pressing release button.
- Disengage fuel delivery line - 2 - .
- Remove fuel delivery unit.

NOTE:
- When removing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor G .
- Be aware that fuel is still in the fuel delivery unit.

Installing
Installation is in reverse order of removal. Note the following:

NOTE:
- Replace seal.
- When inserting fuel delivery unit, be sure not to bend Fuel Level Sensor G.
- Make sure fuel hoses are seated securely.

- Insert fuel delivery unit into fuel tank with locking flange set aside.
- Attach fuel delivery line - 2 - .
- Push suction jet pipe - 1 - onto suction jet pump until it engages audibly.

Make sure fuel hoses are routed correctly:







- The fuel supply line - 1 - must be routed between guide tube - 4 - and supports - 2 - for fuel return line. Also, it must be routed around outside of guide tube - 3 -.
- Insert guide tubes - 3 - and - 4 - of locking flange into guide holes - arrows - of fuel delivery unit.

NOTE: To improve clarity, the fuel delivery unit is shown without the fuel tank.

- Install new locking flange seal dry.
- Press locking flange down against spring pressure and bring it into installation position.







- Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.







- Tighten locking ring.
- Connect battery. Observe safety precautions after connecting battery.
- After replacing fuel delivery unit, there should be a fuel pump adaptation on vehicles with 4-cyl. TFSI engine.

Torque specifications

Locking ring for fuel delivery unit 145 Nm