Fuel Supply Unit, Removing and Installing
Observe Safety measures Technician Safety Information
Observe Rules of cleanliness Vehicle Damage Warnings
Required special tools, testing equipment and auxiliary equipment
- 3217 Union nut wrench
- 3307 Fuel pump wrench
- VAG1275 Hose clamp pliers
Removing
CAUTION! Obtain the radio Anti-theft code from the customer before disconnecting the Battery Ground strap.
- Disconnect Battery Ground strap with ignition switched OFF
- Open fuel-filler cap briefly and close again.
- If necessary, drain fuel tank using fuel cart. Service and Repair
NOTE: The fuel tank must not be filled more than 1/3 maximum.
- Remove connector flange cover under luggage compartment trim.
WARNING! Fuel system is under pressure! Before opening, place clean cloths around the connections to be opened. Carefully loosen the connections to relieve pressure.
- Mark return line -2- and supply line -3- and pull off of cover flange.
- Unlatch and disconnect 4-pin harness connector -1-.
- Unscrew union nut with 3217 wrench.
- Remove cover flange and sealing ring from fuel tank opening.
- Disconnect fuel level sensor harness connector on inside of cover flange.
- Disconnect return line on inside of cover flange by pressing unlatch buttons.
- Insert 3307 fuel pump wrench through fuel tank opening and place on inner section of surge housing.
- Using wrench 3307, turn surge housing inner section approx. 15° to the left up to the stop and take fuel pump out complete with inner section of housing.
NOTE: If the supply unit is replaced, empty the old supply unit of any remaining fuel before properly disposing of it.
Cover flange and surge housing inner section, pre-assembling
If cover flange and supply unit were separated
- Pre-assemble parts. Fuel Supply Unit and Fuel Level Sensor, Component Overview
- Angle position cover flange to inner section of surge housing 10°
- Press together clamps for supply line (between pump and cover flange) using VAG 1275 pliers.
- Attach wiring to fuel pump
- M4: 1.5 Nm (13 in. lb), M5: 2 Nm (18 in. lb)
NOTE: Install a toothed washer beneath each of the nuts.
- Attach wiring using fuel-resistant cable ties.
Installing
Installation is performed in the reverse order of the removal procedure, during installation note the following:
CAUTION! Always refer to the latest parts catalog or contact your Audi Parts Department to ensure that you use original equipment fuel hose clamps.
- Install surge housing inner section, supply hose and cover flange in fuel tank.
- Place inner section of surge housing into outer section of surge housing (in tank) in such a way that notch 1 on inner section of surge housing matches mark 2 on outer section of surge housing.
- The inner section of the surge housing can be pressed downward until it is clearly heard to engage.
- Put fuel pump wrench 3307 in place and turn surge housing inner section with pump to the right approx. 15° to the stop. The notch -1- will then be in front of the marking -3- (bayonet closure).
NOTE: For clarity, the inner and outer surge housing sections are shown without the tank.
- When installing, turn the cover flange in direction of arrow as shown in illustration.
- Connect the return line inside on the cover flange.
NOTE:
- Always use new O-rings.
- Lubricate O-rings with fuel or coat with a lubricant.
- Place the new gasket (dry) for the cover flange into the opening of the fuel tank.
- Wrap fuel level sensor wiring once around the supply line (in fuel tank) and install on cover flange.
- Connect cover flange to fuel tank
- Installation for vehicles with Front-Wheel Drive: -arrow 2- must be opposite -arrow 3-.
NOTE: -Arrow 1- applies to vehicles with All-Wheel Drive (Not applicable).
- Tighten union nut with 3217 wrench.
- 60 Nm (44 ft lb)
NOTE: Ensure that hose guide (item 7 in article "Fuel Supply Unit and Fuel Level Sensor, Component Overview") is kept in position while tightening the union nut. Fuel Supply Unit and Fuel Level Sensor, Component Overview
- Connect wiring and harness connector.
NOTE: Ensure that fuel hoses fit tight.
- Connect Ground strap to Battery with ignition switched OFF
- After connecting Battery, input radio anti-theft code.
- Run door windows up to stop using the window switches.
- Operate all window lifters again for at least 1 second in "closed" position to activate automatic up/down.
- Set the clock.
Tightening torque
Component Nm (ft lb)
Union nut for cover flange 60 (44 ft lb)