Removing and installing fuel pump control unit J538 - vehicles with FSI engine from 06.2004 onwards — AUDI

Removing and installing
fuel pump control unit
J538
- vehicles with FSI engine from 06.2004 onwards
Removing
Observe safety precautions
Chapter
.
Observe rules for cleanliness
Chapter
.
WARNING
Risk of accident caused by weight of fuel tank
Fuel tank must be empty when lowering it. Drain the tank if necessary. Procedure
Chapter
.
Caution
To prevent damage to the electronic components when disconnecting the battery:
Observe notes on procedure for disconnecting the battery
Rep. Gr.
27
.
Switch off ignition.
Saloon:
Fold up luggage compartment floor lining.
Avant:
Remove luggage compartment load surface
1
and spare wheel well cover plate
2
.
All vehicles:
Use screwdriver
2
to release retaining clips
arrows
and detach cover
1
.
Disconnect earth cable at negative terminal of battery
arrow
.
Open the tank flap.
Clean area around fuel filler neck.
Remove filler cap
arrow
from fuel filler neck.
Seal opening of fuel filler neck with a piece of clean foam or similar to prevent dirt from dropping into the tank.
Remove rear wheel (right-side).
Remove rear right wheel housing liner
Rep. Gr.
66
.
Disconnect breather pipe/hose
3
from fuel filler neck (press release tabs).
Remove bolts
1
and
2
for fuel filler neck.
Remove cover
1
from underside of vehicle (rear right).
WARNING
Risk of accident caused by weight of fuel tank
Fuel tank must be empty when lowering it.
Loosen bolts
1, 2, 3, 4, 8, 9
by turning not more than 8 turns.
Unscrew bolts
5, 6, 7
.
Remove rear seat bench
Rep. Gr.
72
.
Unscrew cover for flange (right-side)
arrows
.
Unplug electrical connector
arrow
at flange.
Mark fuel supply pipe
1
and fuel return pipe
2
.
WARNING
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.
Detach both pipes from flange (press release tabs).
Vehicles with auxiliary heater:
In addition, disconnect fuel line leading to metering pump for auxiliary heater by pressing release tab.
All vehicles:
Remove bolts
arrows
.
Pull
fuel pump control unit
J538
together with bracket out between fuel tank and underbody towards inside.
Installing
Tightening torques
Chapter
and
Fig.
Installation is carried out in the reverse order; note the following:
Tighten bolts for securing straps and support bracket
1 ... 9
.
Secure fuel filler neck with earth connection using bolts
1
and
2
.
WARNING
Risk of explosion caused by electrostatic discharge.
After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel filler neck and a bare metal part on the body:
Specification: approx. 0 Ω
Secure breather pipe
3
to fuel filler neck.
Install rear right wheel housing liner
Rep. Gr.
66
.
Install rear seat bench
Rep. Gr.
72
.
Connect battery. Observe notes on procedures required after connecting battery
Rep. Gr.
27
.
Vehicles with auxiliary heater:
Let auxiliary heater run with full load for 10 minutes to bleed fuel line going to metering pump.