Dismantling fuel delivery unit - 4, 5, 6 and 8-cyl. engine (code letters AAH, AAN, ABC, ABH, ABY, ACK, ACZ, ADR, AEC, AEJ) — AUDI

AAE AAH AAN AAR ABB ABC ABH ABK ACE ACK ACZ ADA ADR ADW AEC AEJ AHK
Inner part of baffle housing
Fuel pump
Different versions (Bosch or VDO)
Removing and installing
=> Fig.
20-153
Pre-assembly => Page
20-151
Electrical checking => Page
20-110
Checking holding pressure

=> Injection and Ignition System; Repair Group 24
Injection and Ignition System

Wire
For fuel pump

Washer
M4 = 1.1 Nm
M5 = 1.6 Nm
Hose clamp
Use V.A.G 1275 to secure

Fuel supply pipe
Fuel pump/sender housing
Pre-assembly => Page
20-151

Wire
Connector
For fuel pump
Installation position => Page
20-152

Pre-assembling fuel pump (Bosch) and fuel supply pipe

Fit fuel supply pipe -2- with new tab-type hose clamp -4- at fuel pump -1- as shown.
To do so, align fuel supply pipe at an angle of β = 30° to electrical connections.
Align tab-type hose clamp at an angle of
α = 45° to edge of housing.
Use V.A.G 1275 to secure tab-type hose clamp.
c = 3 mm

Lay wiring -3- to fuel pump along fuel supply pipe.
Secure wiring with a total of 5 fuel-resistant cable ties. Attach upper cable tie at marked location:
a = Effective wire length 120 mm
b = Effective length of fuel supply pipe 120 mm

Pre-assembling fuel pump (VDO) and fuel supply pipe

Fit fuel supply pipe -2- with new tab-type hose clamp -4- at fuel pump -1- as shown.
Align fuel supply pipe at an angle of β = 40° to electrical connections.
Align tab-type hose clamp at an angle of
α = 45° to edge of housing.
Use V.A.G 1275 to secure tab-type hose clamp.
c = 5 mm

Secure wiring with a total of 5 fuel-resistant cable ties. Attach upper cable tie at marked location:
a = Effective wire length 120 mm
b = Effective length of fuel supply pipe 120 mm

Fig.1
Removing and installing fuel pump (Bosch and VDO)

Fuel delivery unit dismantled

Removing

Use screwdriver to press both locking lugs at baffle housing outwards and at the same time pull fuel pump slightly upwards to prevent re-engagement of locking lugs.
Repeat procedure at second shoulder of fuel pump.
Twist fuel pump and pull it upwards out of baffle housing.

Installing

Install in reverse order, paying attention to the following:

Installation position: Offset connection at bottom of fuel pump must be inserted in hole in inner part of baffle housing