Fuel Delivery Unit
Fuel Delivery Unit
Special tools, testers and auxiliary items required
• Wrench (T10202)
Removing
Follow all safety precautions. Refer to => [ Safety Precautions ] General Information.
Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Disconnect the battery.
TT Roadster:
• It is necessary to remove the fuel tank first in order to be able to remove the fuel delivery unit on the Audi TT Roadster.
- Removing fuel tank, refer to => [ Fuel Tank with Attachments ] Fuel Tank with Attachments.
TT Coupe:
Danger due to escaping fuel.
• To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 1/3 full.
- Empty fuel tank if necessary, refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove rear seat bench.
- Unclip catches - arrows - of right connector flange cover.
- Disconnect the connector - arrow - from the locking flange.
- Mark the fuel supply line - 1 - and fuel return line - 2 -.
There is a risk of injury because the fuel is under high pressure.
• To reduce the pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Pull both lines from locking flange, by pressing the release buttons.
TT Roadster:
- Mark the fuel supply - 1 - and the fuel return - 2 - lines on the removed fuel tank.
- Pull both lines from locking flange, by pressing the release buttons.
TT Coupe:
Danger due to escaping fuel.
• To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 1/3 full.
All Vehicles:
- Remove locking ring with (T10202).
- Pull the right sealing flange and seal of the fuel delivery unit out from the opening in the fuel tank and lay aside with lines still attached.
- Through the fuel tank opening, separate the suction jet pipe - 2 - from suction jet pump, by pressing release button.
- Disconnect fuel delivery line - 1 - by pressing the release - arrow -.
- Remove the fuel delivery unit.
• When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor (G).
• Be sure there is still some fuel inside the fuel delivery unit.
Installing
• Tightening specification, refer to => [ Fuel Delivery Unit and Fuel Level Sensor (G) Overview ] Fuel Delivery Unit and Fuel Level Sensor (G) Overview.
Install in reverse order, paying attention to the following:
• Replace seal.
• Do not bend the fuel level sensor when inserting the fuel delivery unit.
• Make sure the fuel hoses are secure.
- Insert the fuel delivery unit into fuel tank with locking flange set aside.
- Push the fuel delivery line - 1 - on until it engages audibly.
- Push the suction jet pipe - 2 - onto the suction jet pump until it engages audibly.
- Install the new locking flange seal dry.
- Insert guide of locking flange into guide at fuel delivery unit, observing spring while doing so.
Risk of leaking.
• When inserting sealing flange, sealing ring must not be damaged or crushed.
- Press locking flange down against spring pressure and bring it into installation position.
• The tab - 2 - on the locking flange faces toward the arrow marking and must lie between tabs - 1 and 3 - on the fuel tank.
• - Arrow - points in direction of travel.
- Tighten locking ring.
TT Coupe:
- Install rear seat bench.
- Connect the battery. Observe safety precautions after connecting battery.
TT Roadster:
- Installing fuel tank: Refer to vehicles with all wheel drive => [ Installing ] Fuel Tank with Attachments.
All Vehicles:
- After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.
- On vehicles with TFSI engine with toothed belt drive, a fuel pump adaptation must be performed after replacing the fuel delivery unit. Refer to => [ Toothed Belt Drive, Performing a Fuel Pump Adaptation after Replacing Fuel Delivery Unit ] Toothed Belt Drive, Performing a Fuel Pump Adaptation after Replacing Fuel Delivery Unit.