Removing and installing fuel delivery unit/fuel gauge senders - TFSI vehicles — AUDI

🧭 Before you start

Fits: Audi A4 B9 (8W, 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 .
• 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.
• The fuel delivery unit is shown without fuel lines for greater clarity.
• Ignore other (items).
• Plug in electrical connectors on flange and make sure they are securely engaged.

🔧 Engine codes this applies to

📋 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. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect earth wire from battery terminal Electrical system27Battery; Disconnecting and connecting battery.
5. Move front seats all the way up and forwards.

6. Remove seat bench/individual seats General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
7. Remove bolts (arrows) and detach cover (1) for flange.
8. Release retainer catches and unplug electrical connectors (1 and 3) on flange.
9. Depending on equipment version: Release retainer catch and unplug electrical connector (2) for metering pump for auxiliary heater.
10. Depending on equipment version: Disconnect fuel line (1) leading to metering pump for auxiliary heater at flange. Disconnecting plug-in connectors
11. ⚠ The fuel system is pressurised.Risk of injury as fuel may spray out.Wear safety goggles.Wear protective gloves.Release pressure (wrap clean cloth around connection and open connection carefully). — Disconnect fuel line (2) from flange. Disconnecting plug-in connectors
12. ⚠ 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.
13. Pull flange (1) slightly out of opening in fuel tank and detach seal (2).
14. Carefully pull flange with fuel lines out of opening in fuel tank.
15. Release retainer catches and unplug electrical connectors on flange.
16. Reach into opening in fuel tank and disconnect supply line (arrow) for suction-jet pump. Disconnecting plug-in connectors
17. Reach into opening in fuel tank and disconnect supply line (arrow) for suction-jet pump. Disconnecting plug-in connectors
18. Reach through opening in fuel tank, press catches (2, 3) in direction of (arrows) one after the other and at the same time release fuel delivery unit (1).
19. ⚠ Safety risk from escaping fuel: the fuel delivery unit is still filled.Use a cloth to catch escaping fuel. — Carefully pull fuel delivery unit out of opening in fuel tank. [Note: The fuel delivery unit is shown without fuel lines for greater clarity.] [Note: Renew seal after removing.Make sure that fuel delivery unit is seated securely.]
20. Equipment version with auxiliary heater: Make sure that suction pipe (2) (for extracting fuel) for auxiliary/supplementary heater is correctly inserted and engaged (arrow) in guide on fuel delivery unit (5). [Note: Ignore other (items).]
21. Carefully insert fuel delivery unit in fuel tank.
22. Reach through opening in fuel tank and bring fuel delivery unit into installation position.
23. Press fuel delivery unit (1) downwards into catches on baffle housing so that it clicks into place.
24. Press fuel delivery unit down again and then pull to check that catches (2 and 5) are correctly engaged.
25. Reach through opening in fuel tank and connect supply line (arrow) for suction-jet pump so it engages audibly.
26. Reach through opening in fuel tank and connect supply line (arrow) for suction-jet pump so it engages audibly.
27. Plug in electrical connectors on flange and make sure they are securely engaged.
28. Install new seal (1) for flange (seal must be installed dry).
29. ⚠ Leakage riskThe seal must not be pinched or damaged when installing the flange. — Fit flange in correct installation position.
30. Press flange on firmly, fit locking ring and secure using wrench T10202.
31. Connect fuel lines so they engage audibly.
32. Plug in electrical connectors and make sure they are securely engaged.
33. Put at least 5 litres of fuel into tank after installing fuel delivery unit. [Note: The fuel pump must not be allowed to run in an empty fuel tank.]
34. Install seat bench/individual seats General body repairs, interior72Rear seats; Removing and installing seat bench/individual seats.
35. Connect battery and perform steps required after re-connecting battery Electrical system27Battery; Disconnecting and connecting battery.
36. Depending on equipment version: Bleed fuel line leading to metering pump for auxiliary heater .

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