Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

CAUTION!
• To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 1/4. Empty fuel tank if necessary.

• Observe safety precautions when disconnecting the battery.

All except Audi RS4:

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





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





Audi RS4:

- Raise luggage compartment floor covering and secure.

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





All:

- Open fuel filler flap briefly and then close again.

- Remove rear seat bench.

- Remove cover - arrows - for right locking flange.





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





CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

- Pull both lines from locking flange, by pressing the 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 with Wrench (T10202).





- Remove locking flange and seal from opening in fuel tank and lay aside the locking flange with lines still connected.

- Disconnect the suction jet pipe - 1 - to suction jet pump by pressing release button.





- Disengage the fuel delivery line - 2 -.

- Remove fuel delivery unit.

• 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:

• Replace seal.

• When inserting fuel delivery unit into fuel tank, be sure not to bend Fuel Level Sensor (G).

• Ensure fuel hoses are seated securely.

- Insert fuel delivery unit into fuel tank with locking flange set aside.

- Attach the fuel delivery line - 2 -.

- Push the suction jet pipe - 1 - onto the suction jet pump until it engages audibly.

Make sure fuel hoses are routed correctly:





• The fuel supply line - 1 - must be routed between the guide tube - 4 - and the supports - 2 - for fuel return line. Also, it must be routed around the outside of the guide tube - 3 -.

- Insert the guide tubes - 3 - and - 4 - of the locking flange into the guide holes - arrows - of the fuel delivery unit.

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

- Install the new locking flange seal dry.

- Press locking flange down against spring pressure and bring it into installation position.

• The 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.

- Fill vehicle with at least 5 liters of fuel after installing fuel level sensor.

- After replacing fuel delivery unit, there should be a fuel pump adaptation on vehicles with 4-cyl. TFSI engine. Refer to => [ Fuel Pump Adaptation after Replacing Fuel Delivery Unit, Vehicles with 4-cyl. TFSI Engine ] Vehicles With All Wheel Drive as of 11.2004.

Tightening Specifications