Removing and installing fuel pump control unit J538 — AUDI

Removing and installing
fuel pump control unit
J538
Special tools and workshop equipment required
Removal lever
80-200
Removing
Observe safety precautions
Chapter
.
Observe rules for cleanliness
Chapter
.
Move seats as far forward as possible and tip down backrests.
WARNING
Large amounts of fuel can escape.
The fuel tank must not be more than
1
/
4
full when removing the fuel pump control unit, otherwise a large amount of fuel will escape.
Drain fuel tank if necessary
Chapter
.
Caution
To prevent irreparable damage to the electronic components when disconnecting the battery:
Observe notes on procedure for disconnecting the battery.
With ignition switched off, disconnect earth cable
arrow
at battery
Electrical system
Rep. gr.
27
.
R8 GT:
Remove rollover bars
General body repairs, interior
Rep. gr.
69
.
R8 Coupé and R8 GT:
Remove rear shelf
Rep. gr.
70
.
Remove side trim
Rep. gr.
70
.
Unscrew positive wire
4
.
Unplug electrical connectors
3
at connector point, detach connector point from bracket for control units and move connector point to the side.
Detach relay and fuse holder (rear right) from bracket for control units
arrows
and move relay and fuse holder aside.
Note
Disregard
items 1, 2, 5
.
Unplug electrical connectors for control units, unbolt bracket for control units
arrows
and remove bracket from vehicle.
Pry electrical wiring harness off base of back panel using
removal lever
80-200
and move harness clear.
R8 Spyder:
Remove convertible roof unit
Rep. gr.
61
.
All vehicles (continued):
Fold back insulating mat above cover for fuel tank flange.
Unscrew bolts
1 ... 4
and remove cover for flange on fuel tank (right-side).
Unplug electrical connector
arrow
on flange (right-side).
WARNING
Risk of injury caused by fuel.
To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection.
Press release tabs and disconnect fuel lines
1, 2 and 3
on flange (right-side).
Note
There can be 2 or 3 fuel lines, depending on version.
WARNING
Large amounts of fuel can 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
Chapter
.
Remove locking ring on flange (right-side) with
wrench
T10202
.
Remove flange and seal for fuel delivery unit from opening in fuel tank.
Press release tab and detach fuel line
1
on inside of flange.
Unplug electrical connectors
2, 3 and 4
and take off flange with seal.
Note
Use e.g. wide adhesive tape to seal off opening for flange to prevent dirt from dropping into fuel tank chamber (right-side).
Remove bolts
1
and
2
.
Move fuel lines down.
Slightly lift floor panel in area of flange by hand and remove
fuel pump control unit
J538
between floor panel and fuel tank flange.
Unplug electrical connector at
fuel pump control unit
J538
.
Installing
Installation is carried out in the reverse order; note the following:
Tightening torques
Fig.
“Cover for flange on fuel tank - tightening torque”
.
Fig.
“
Fuel pump control unit
J538
- tightening torque”
.
Install flange for fuel delivery unit
Anchor
.
Check fuel tank for leaks
Chapter
.
Install connector point and relay and fuse holder (rear right)
Electrical system
Rep. gr.
97
.
R8 Spyder:
Install convertible roof unit
Rep. gr.
61
.
All vehicles (continued):
Connect battery and perform steps required after connecting battery
Electrical system
Rep. gr.
27
).