Removing and installing fuel delivery unit - vehicles with 4-cylinder engine — AUDI

AFB AFF AFN AHH AHU AJM AKN ATJ AVG
Special tools and workshop equipment required

Ring nut spanner 3217
Fuel pump spanner 3307
Hose clamp pliers V.A.G 1275

Note:

The illustration shows the correct routing of hoses inside the tank.

Baffle housing
Fuel return hose
From suction jet pump

Flange
Suction jet pump
Fuel hose
From fuel pump to suction jet pump

Fuel supply hose

Observe safety precautions=> Page
20-1
.

Observe rules for cleanliness => Page
20-3
.

Removing

The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Drain fuel tank if necessary.
Procedure => Page
20-107
.
Detach floor trim in luggage compartment.
Unbolt cover for flange.
Disconnect fuel return pipe -2- and fuel supply pipe -3- from flange.
Release and unplug connector -1-.

Remove union nut with spanner 3217.
Remove flange and seal out of opening in fuel tank.

Pull fuel return hose -2- off inside of flange -1- (use uncoupling tool T40020 or press release tabs).
Unplug connector for fuel gauge sender on inside of flange.

Disconnect fuel hose -2- from fuel pump at connection -1- for suction jet pump (use uncoupling tool T40020 or press release tabs).

Press retaining tab, and at the same time pull the sender unit out of baffle housing in fuel tank -arrows-.

Insert fuel pump spanner 3307 through opening in fuel tank and apply spanner to fuel delivery unit.
Using spanner 3307, turn fuel delivery unit anti-clockwise as far as it will go (approx. 15°), and take out fuel delivery unit.

Installing

Install in reverse sequence; note the following points:

Note:

Secure all hose connections with the correct hose clips (same as original equipment)

=> Parts catalogue

Place fuel delivery unit in fuel tank.

Fit fuel delivery unit into outer section of baffle housing (in tank) so that notch -1- on fuel delivery unit is aligned with marking -2- on outer section of housing.
The fuel delivery unit should move down noticeably.

Apply fuel pump spanner 3307 and turn fuel delivery unit clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting).

Insert fuel gauge sender into guide on outer section of baffle housing and press down until it clicks into place.

Notes:

Use new O-rings.
Ensure that O-rings are not trapped - use lubricant if necessary.

Connect fuel hose -2- (from fuel pump) to connection -1- for suction jet pump.
Wrap fuel gauge sender wire once around the supply hose (in fuel tank) and connect at flange.

Connect return hose -2- to inside of flange -1-.
Fit new sealing ring for flange in fuel tank opening (sealing ring should be dry).

Fit flange into fuel tank; note correct installation position:
Installation position for vehicles with four-wheel drive:
-arrow 1- must be aligned with -arrow 2-.

Note:

-Arrow 3- is for vehicles with front-wheel drive (can be disregarded).

Tighten union nut with spanner 3217 (60 Nm).
Connect pipes and plug in the connector.