Removing and installing fuel delivery unit (vehicles with four-wheel drive) — AUDI

AFY APT ARG AVV
Observe notes => Page
20-1
.

Observe safety precautions=> Page
20-2

Observe rules for cleanliness => Page
20-3

Special tools, testers and auxiliary items

Ring nut spanner 3217
Fuel pump spanner 3307
Hose clamp pliers V.A.G 1275
Fuel extractor V.A.G 1433 A

Removing

Notes:

The fuel tank must not be more than 1/3 full.
If necessary, drain tank using fuel extractor V.A.G 1433 A.

Obtain radio code on vehicles with coded radio.
With ignition switched off,disconnect battery earth strap.

Detach trim in luggage compartment.
Unbolt cover for flange on fuel tank under floor trim in luggage compartment.
Mark the supply pipe -2- and return pipe -3-, then pull pipes off flange.
Release 4-pin connector -1- and unplug.

Remove union nut with spanner 3217.
Remove flange and seal out of opening in fuel tank.
Unplug connector for fuel gauge sender on inside of flange.
Pull fuel return pipe off inside of fuel delivery unit flange (press release tabs).

Insert fuel pump spanner 3307 through opening in fuel tank and apply spanner to inner section of baffle housing.
Using spanner 3307 turn inner section of baffle housing anti-clockwise as far as it will go (approx. 15°), and take out fuel pump with inner section of baffle housing.

Pre-assembling flange and inner section of baffle housing

If flange has been separated from fuel delivery unit, pre-assemble components before installing=>Page
20-42
.

Angle between flange and inner section of baffle housing: 10°

Compress clamps for supply pipe (between pump and flange) using hose clamp pliers V.A.G 1275.
Connect electrical wires onto fuel pump
(M4: 1.5 Nm; M5: 2 Nm)

Note:

Fit a toothed washer under each nut.

Secure the electrical wires using a fuel-resistant cable tie.

Installing

Insert inner section of baffle housing, supply pipe and flange in fuel tank.
Fit inner section of baffle housing into outer section of baffle housing (in tank) so that notch -1- on inner section of housing is aligned with marking -2- on outer section of housing.
The inner section of baffle housing should move down noticeably.

Note:

Baffle housing is shown without fuel tank for a clearer illustration.

Apply fuel pump spanner 3307 and turn pump together with inner section of baffle housing clockwise as far as it will go (approx. 15°). Notch -1- will then be aligned with marking -3- (bayonet fitting)=>Fig.A20-0112.

When installing, turn flange in a clockwise direction, as indicated in illustration.
Connect return pipe on inside of flange.

Note:

Lubricate O-rings with fuel or other lubricant.

Wrap fuel gauge sender wire once around the return pipe (in fuel tank) and connect at flange.

Note:

Lubricate the flange seal with fuel before fitting.

Insert flange in fuel tank; note correct installation position:
Marking onflange must coincide with marking on fuel tank
-arrows-.
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.
Connect pipes and plug in the connector.

Note:

Ensure that fuel pipes are securely seated.

Tightening torque

Component · Nm
Union nut for flange · 60