Removing and installing fuel delivery unit/fuel gauge sender - vehicles with front-wheel drive — AUDI

🧭 Before you start

Fits: Audi A3 (8V, 2012–2020)

• Opens: fuel
• Renewed: seal

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• 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 .
• 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. — 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

📋 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 1/4 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.
9. Equipment version with auxiliary heater: Disengage electrical connector (3) for metering pump for auxiliary heater on flange and move to one side.
10. ⚠ 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. — Equipment version with auxiliary heater: Release hose clip and detach fuel line (3) to metering pump for auxiliary heater from flange.
11. Disconnect fuel lines (1 and 2) on flange.
12. To do so (depending on equipment), press connection piece (1) down as far as stop (arrow A) and hold.
13. Press release tabs (2)(arrows B) and pull connection piece off connection.
14. ⚠ 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. — Remove locking ring using wrench T10202.
15. Pull flange (3) slightly out of opening in fuel tank.
16. Remove seal (1) from opening in fuel tank.
17. Carefully pull flange with fuel line (2) out of opening in fuel tank.
18. ⚠ Safety risk from escaping fuel: the fuel delivery unit is still filled.Use a cloth to catch escaping fuel. — Carefully pull fuel delivery unit with fuel gauge sender 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.When inserting the fuel delivery unit, make sure you do not bend the float arm of the fuel gauge sender.]
19. Carefully guide fuel delivery unit with fuel gauge sender in through opening in fuel tank.
20. Install new seal (1) for flange (seal must be installed dry).
21. ⚠ Leakage riskThe seal must not be pinched or damaged when installing the flange. — Fit flange in correct installation position.
22. Press flange down against spring pressure.
23. Fit locking ring and secure using wrench T10202.
24. Connect fuel lines so they engage audibly.
25. Press fuel lines in again and then pull to check that plug-in connectors are correctly engaged.
26. Vehicles with auxiliary heater: Install fuel line to metering pump for auxiliary heater at flange Auxiliary/supplementary heater82Fuel supply system.
27. Install rear seat bench General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
28. Reset learnt values after renewing fuel delivery unit , Guided Functions, Reset learnt values.
29. Put at least 5 litres of fuel into tank after installing fuel delivery unit.

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