Removing and installing fuel pump control unit J538 — AUDI

🔧 Engine codes this applies to

📐 52 workshop diagrams for ALT

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Observe safety precautions .
2. Observe rules for cleanliness .
3. Move seats as far forward as possible and tip down backrests.
4. ⚠ 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 .
5. ⚠ 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 system27.

6. Remove rollover bars General body repairs, interior69.
7. Remove rear shelf 70.
8. Remove side trim 70.
9. Unscrew positive wire (4).
10. Unplug electrical connectors (3) at connector point, detach connector point from bracket for control units and move connector point to the side.
11. 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).]
12. Unplug electrical connectors for control units, unbolt bracket for control units (arrows) and remove bracket from vehicle.
13. Pry electrical wiring harness off base of back panel using removal lever80-200 and move harness clear.
14. Remove convertible roof unit 61.
15. Fold back insulating mat above cover for fuel tank flange.
16. Unscrew bolts (1 ... 4) and remove cover for flange on fuel tank (right-side).
17. Unplug electrical connector (arrow) on flange (right-side).
18. ⚠ 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.]
19. ⚠ 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 .
20. Remove locking ring on flange (right-side) with wrench T10202.
21. Remove flange and seal for fuel delivery unit from opening in fuel tank.
22. Press release tab and detach fuel line (1) on inside of flange.
23. 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).]
24. Remove bolts (1) and (2).
25. Move fuel lines down.
26. Slightly lift floor panel in area of flange by hand and remove fuel pump control unit J538 between floor panel and fuel tank flange.
27. Unplug electrical connector at fuel pump control unit J538.
28. Install flange for fuel delivery unit .
29. Check fuel tank for leaks .
30. Install connector point and relay and fuse holder (rear right) Electrical system97.
31. Install convertible roof unit 61.
32. Connect battery and perform steps required after connecting battery Electrical system27).

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