Removing and installing fuel delivery unit/fuel gauge sender — AUDI

🧭 Before you start

Fits: Audi Q3 (8U, 2011–2018)

• Opens: fuel
• Renewed: seal

Don't miss

• Danger! Fuel may escape.The fuel tank must not be more than 1/3 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Drain fuel tank if necessary .
• Danger! Fuel may escape.The fuel tank must not be more than 1/3 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Remove locking ring using wrench T10202.
• When removing the fuel delivery unit, make sure you do not bend the float arm of the fuel gauge sender.
• Install new seal (1) for flange (seal must be installed dry).
• Leakage riskThe seal must not be pinched or damaged when installing the flange. — Fit flange in correct installation position.

🔧 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. Move front seats all the way forwards.
4. Switch off ignition.
5. Remove rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.

6. ⚠ Danger! Fuel may escape.The fuel tank must not be more than 1/3 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Drain fuel tank if necessary .
7. Unclip cover (1) for flange (right-side) at retainers (arrows) using removal wedge3409.
8. Release retainer catches and unplug electrical connectors (1) and (2) on flange (right-side).
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 (1 and 2) from flange. Disconnecting plug-in connectors
10. ⚠ Danger! Fuel may escape.The fuel tank must not be more than 1/3 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Remove locking ring using wrench T10202.
11. Pull flange (2) slightly out of opening in fuel tank.
12. Remove seal (1) from opening in fuel tank.
13. Carefully pull flange with fuel line (3) and electrical wiring out of opening in fuel tank.
14. Reach into opening in fuel tank and disconnect supply line (3) for suction-jet pump. Disconnecting plug-in connectors
15. Reach through opening in fuel tank, release supply line (2) at retainers (1) and disconnect from fuel delivery unit.
16. ⚠ Safety risk from escaping fuel: the fuel delivery unit is still filled.Use a cloth to catch escaping fuel. — Carefully pull fuel delivery unit (1) with fuel gauge sender (2) out through opening in fuel tank by turning and tilting it as required. [Note: When removing the fuel delivery unit, make sure you do not bend the float arm of the fuel gauge sender.] [Note: Renew seal.Make sure that fuel hoses are securely fitted.When plugging in electrical connectors, make sure they engage correctly.When inserting the fuel delivery unit, make sure you do not bend the float arm of the fuel gauge sender.]
17. Carefully insert fuel delivery unit with fuel gauge senderG in fuel tank.
18. Reach through opening in fuel tank and clip supply line (1) onto fuel delivery unit (3) so it engages audibly.
19. Connect supply line for suction-jet pump (2) so it engages audibly.
20. Press supply line for suction-jet pump and supply line in again and then pull to check that plug-in connectors are correctly engaged.
21. Route fuel hoses and electrical wiring as shown in illustration.
22. Position flange (4) with guide tubes (2) and (3) and fuel return pipe (5) on fuel delivery unit (1).
23. Insert guide tubes and fuel return pipe into guides as shown in illustration.
24. Install new seal (1) for flange (seal must be installed dry).
25. ⚠ Leakage riskThe seal must not be pinched or damaged when installing the flange. — Fit flange in correct installation position.
26. Press flange down against spring pressure.
27. Fit locking ring and secure using wrench T10202.
28. Connect fuel lines so they engage audibly.
29. Press fuel lines in again and then pull to check that plug-in connectors are correctly engaged.
30. Install rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
31. Put at least 5 litres of fuel into tank after installing fuel delivery unit.

Other AUDI procedures

• Removing and installing exhaust gas temperature sender 3G495 · 1 torque figures
• Checking return flow rate of injectors at starter cranking speed
• Removing and installing engine control unit J623 – Audi
• Checking for injectors sticking open – Audi A6/A7 C7
• Removing and installing air cleaner (bottom section)
• 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