Removing and installing fuel delivery unit - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive) — AUDI

🧭 Before you start

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

• Opens: fuel
• Renewed: seal

Don't miss

• 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 .
• The plastic detent on the threaded ring will break off when the union nut is unscrewed - this can be disregarded.
• When removing fuel delivery unit, make sure you do not bend float arm of fuel gauge sender G.
• The fuel delivery unit is shown without the fuel tank for illustration purposes.
• Swivel fuel delivery unit (1) to left side of vehicle and guide into fuel tank (arrow) (make sure fuel gauge sender (2) is not damaged).

🔧 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 2) on flange.
8. Disengage electrical connector (3) for metering pump for auxiliary heater on flange and move clear.
9. ⚠ The fuel can become extremely hot. This can cause injuries.In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C. Allow the fuel to cool down before disconnecting the lines - danger of scalding.Wear protective gloves.Wear safety goggles.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. — Disconnect fuel lines (2) and (3) on flange (press release tabs).
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. ⚠ Safety risk from escaping fuel: the fuel delivery unit is still filled.Use a cloth to catch escaping fuel. — Swivel fuel delivery unit (1) 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.]
14. Take out fuel gauge senderG(item 2) from opening in fuel tank.
15. Detach suction pipe (3) (press release tab (1)).
16. Press release tab (arrow) and unplug electrical connector (2) for fuel gauge sender 2G169. [Note: The fuel delivery unit is shown without the fuel tank for illustration purposes.] [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. Guide suction pipe (3) out of fuel tank and connect suction pipe so it engages audibly.
18. Plug in electrical connector (2) for fuel gauge sender 2G169.
19. Insert fuel gauge senderG(item 2) in fuel tank.
20. Swivel fuel delivery unit (1) to left side of vehicle and guide into fuel tank (arrow) (make sure fuel gauge sender (2) is not damaged).
21. Slip new seal (1) onto flange (2) and insert in groove on fuel tank.
22. Slip union nut (1) over your left arm and press flange (2) firmly into installation position (arrow) with your left hand.
23. 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).
24. 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.
25. Keep pressing flange downwards firmly (arrow).
26. 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.
27. ⚠ 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.
28. Connect fuel lines (1, 2, 3).
29. Connect electrical connectors.
30. Install cover for flange .
31. Install rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
32. Put at least 5 litres of fuel into tank after installing fuel delivery unit.
33. Vehicles with auxiliary heater: Bleed fuel supply line leading to metering pump Auxiliary heater, supplementary heater82Fuel supply system.

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