Removing and installing fuel delivery unit - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with four-wheel drive) — AUDI

🧭 Before you start

Drain the tank to no more than a quarter, remove the rear seat bench and the flange cover, unplug the connectors and disconnect the fuel lines. Undo the union nut, lift the flange off, unplug the fuel gauge sender and swivel the unit out. Refit it the same way, fit a new seal, start the union nut at the ten o'clock mark while pressing the flange down, tighten it, reconnect everything and add at least 5 litres of fuel.

Fits: Audi A5 (8T, 2007–2016), Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015)

• Opens: fuel
• Renewed: seal

Don't miss

• The tank must be no more than 1/4 full, or a large amount of fuel will escape.
• Wrap a cloth round fuel line connections when releasing them; the system is under pressure.
• Renew the seal and union nut; do not bend the fuel gauge sender float arm.
• Press the flange down firmly while tightening the union nut so it does not turn.
• Add at least 5 litres of fuel; bleed the auxiliary heater supply line where fitted.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 38 workshop diagrams for CAGA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Observe safety precautions .
2. Observe rules for cleanliness .
3. ⚠ Danger! Fuel may escape.The fuel tank must not be more than 1/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Drain fuel tank if necessary .
4. Move passenger's seat as far to front as possible (if necessary).
5. Remove rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.

6. Unscrew cover for flange (arrows).
7. Release retainer catches with assembly tool T10118 and unplug electrical connectors (1 and 3) on flange.
8. Disengage electrical connector (2) for metering pump for auxiliary heater on flange and move clear.
9. ⚠ Risk of injury - fuel system operates under high pressure.To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection. — Press release tabs and disconnect fuel lines (2) and (3) on flange.
10. Press release tab and disconnect fuel line (1) leading to metering pump for auxiliary heater at flange.
11. ⚠ Danger! Fuel may escape.The fuel tank must not be more than 1/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Unscrew union nut using union nut tool T40068 A(arrow). [Note: The plastic detent on the threaded ring will break off when the union nut is unscrewed - this can be disregarded.]
12. Take flange (2) out of fuel tank and detach seal (1).
13. Unplug electrical connector (3) for fuel gauge sender 2G169 and move wiring clear.
14. Carefully pull fuel delivery unit slightly out of fuel tank.
15. ⚠ Safety risk from escaping fuel: the fuel delivery unit is still filled.Use a cloth to catch escaping fuel. — Swivel fuel delivery unit (2) to left side of vehicle (arrow) and tilt slightly out of fuel tank. [Note: When removing fuel delivery unit, make sure you do not bend float arm of fuel gauge sender G.]
16. Guide fuel gauge senderG(item 1) out of opening in fuel tank and take fuel delivery unit out of fuel tank. [Note: Renew seal and union nut.Take care not to bend float arm of fuel gauge sender G when fitting fuel delivery unit.Ensure that fuel hoses are securely seated.]
17. Make sure that earth connection (1) is securely attached to fuel pressure regulator and flange (arrows).
18. Check that the following connectors are securely seated:
19. Make sure connectors are attached properly; pull to check that they are correctly engaged.
20. Insert float on fuel gauge senderG(item 1) in fuel tank.
21. Swivel fuel delivery unit (2) to left side of vehicle and guide it into fuel tank (arrow) (pay attention to fuel gauge sender).
22. Slip new seal (1) onto flange (2) and insert in groove on fuel tank.
23. Plug in electrical connector (3) for fuel gauge sender 2G169.
24. Slip union nut (1) over your left arm and press flange (2) firmly into installation position (arrow) with your left hand.
25. Take union nut (1) off your left arm with your right hand and at the same time keep pressing down flange (2) firmly with your left hand (arrow).
26. Position union nut (1) with your right hand in such a way that double ridge (5) on ribs aligns with lug (3) of flange (approx. "“ten o'clock position”"). This will make union nut engage immediately with beginning of thread (4) when tightening.
27. Keep pressing flange downwards firmly (arrow).
28. Turn union nut approx. 480° with your right hand until double ridge (1) is in approx. "“two o'clock position”" and at the same time keep on pressing flange downwards firmly with your left hand.
29. ⚠ Take care to avoid leakage at flange.Press flange downwards firmly when tightening union nut to make sure flange does not also turn. — Tighten union nut for flange using union nut tool T40068 A.
30. Connect fuel lines (1, 2, 3).
31. Connect electrical connectors.
32. Install cover for flange .
33. Install rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
34. Put at least 5 litres of fuel into tank after installing fuel delivery unit.
35. Vehicles with auxiliary heater: Bleed fuel supply line leading to metering pump Auxiliary heater, supplementary heater82Fuel supply system.

Other AUDI procedures

• Checking fuel system pressurisation pump G6 (electrical test) - A5 up to model year 2011, A4 up to model year 2012 (vehicles with front-wheel drive)
• Checking fuel delivery rate of fuel system pressurisation pump G6 - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive)
• Checking fuel system pressurisation pump G6
• Removing and installing vacuum unit for exhaust gas recirculation cooler
• Filling and bleeding fuel system
• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures