Removing and installing fuel delivery unit/fuel gauge sender (front-wheel drive) — AUDI

🧭 Before you start

Disconnect the battery, drain the tank below 3/4 if necessary, remove the rear seat bench and unclip the flange cover. Unplug the connector, mark and release the supply and return lines with a cloth around them, unscrew the locking ring and lift the unit out with its seal. Refit with a new dry seal, pressing the flange down so the arrow points forward, and tighten the ring. Reconnect, put at least 5 litres of fuel in the tank and, on TFSI engines with toothed belt drive, adapt the fuel pump.

Fits: Audi TT Mk2 (8J, 2006–2014)

• Renewed: seal

Don't miss

• On the TT Roadster, remove the fuel tank before trying to remove the delivery unit.
• Mark the supply and return lines before release; swapping them causes running faults.
• Install the new flange seal dry and make sure it is not pinched under the flange.
• Do not bend the float arm of the fuel gauge sender during removal or fitting.
• Add at least 5 litres of fuel after installation; adapt the pump on belt-driven TFSI engines.

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

🔧 Engine codes this applies to

📐 56 workshop diagrams for BPY

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

📋 Procedure

1. ⚠ On the TT Roadster, the fuel tank must first be removed before removing the fuel delivery unit. — Remove fuel tank: Rest-of-world vehicles with front-wheel drive , USA vehicles with front-wheel drive .
2. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.
3. ⚠ Large amounts of fuel can escape.The fuel tank must not be more than 3/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Drain fuel tank if necessary: Rest-of-world vehicles with front-wheel drive , USA vehicles with front-wheel drive.
4. Remove rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
5. Unclip retaining tabs (arrows) for flange cover.

6. Unplug electrical connector (arrow) at flange.
7. Mark fuel supply line (1) and fuel return line (2).
8. ⚠ 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. — Detach both lines from flange (press release tabs).
9. With fuel tank removed, mark fuel supply line (1) and fuel return line (2).
10. Detach both lines from flange (press release tabs).
11. ⚠ Large amounts of fuel can escape.The fuel tank must not be more than 3/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. — Unscrew locking ring using wrench T10202.
12. Pull fuel delivery unit with seal out of opening in fuel tank. [Note: When removing fuel delivery unit, make sure you do not bend float arm of fuel gauge sender G.Keep in mind that the fuel delivery unit still contains fuel.] [Note: Renew seal.Take care not to bend float arm of fuel gauge sender G when fitting fuel delivery unit.]
13. Insert fuel delivery unit into fuel tank.
14. Install new seal for flange (seal must be installed dry).
15. ⚠ Leakage riskThe seal must not be pinched or damaged when installing the flange. — Press flange down against spring pressure and move flange into installation position. [Note: The (arrow) points in direction of travel.]
16. Tighten locking ring.
17. Install rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
18. Connect battery. Observe notes on procedure after disconnecting the battery Electrical system27Battery; Disconnecting and connecting battery.
19. Install fuel tank: Rest-of-world vehicles with front-wheel drive , USA vehicles with front-wheel drive .
20. Put at least 5 litres of fuel into tank after installing fuel delivery unit.
21. On vehicles with TFSI engine with toothed belt drive, the fuel pump must be adapted after renewing the fuel delivery unit .

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