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

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

Don't miss

• Disregard (item 1).
• Risk of accident caused by weight of fuel tankFuel tank must be empty when lowering it. — Loosen bolts (1, 2, 3, 4, 8, 9) by turning not more than 8 turns.
• Mark fuel supply pipe (1) and fuel return pipe (2).

🔧 Engine codes this applies to

📐 28 workshop diagrams for AUK

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

📋 Procedure

1. ⚠ To prevent damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery 27. — Switch off ignition.
2. Release the tank flap.
3. Fold up luggage compartment floor lining.
4. Remove luggage compartment load surface (1) and spare wheel well cover plate (2).
5. Use screwdriver (2) to release retaining clips (arrows) and detach cover (1).

6. Disconnect earth cable at negative terminal of battery (arrow).
7. Open the tank flap.
8. Clean area around fuel filler neck.
9. Remove filler cap (arrow) from fuel filler neck.
10. Seal opening of fuel filler neck with a piece of clean foam or similar to prevent dirt from dropping into the tank.
11. Remove rear wheel (right-side).
12. Remove rear right wheel housing liner 66.
13. Disconnect breather pipe/hose (2) from fuel filler neck (press release tabs). [Note: Disregard (item 1).]
14. Unscrew bolts (arrows) for fuel filler neck.
15. Remove cover (1) from underside of vehicle (rear right).
16. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when lowering it. — Loosen bolts (1, 2, 3, 4, 8, 9) by turning not more than 8 turns.
17. Unscrew bolts (5, 6, 7).
18. Remove rear seat bench 72.
19. Unscrew cover for flange (right-side) (arrows).
20. Unplug electrical connector (arrow) at flange.
21. Mark fuel supply pipe (1) and fuel return pipe (2).
22. ⚠ 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).
23. Remove bolts (arrows).
24. Pull fuel pump control unit J538 together with bracket out between fuel tank and underbody towards inside.
25. Tighten bolts for securing straps and support bracket (1 ... 9).
26. Secure fuel filler neck with earth connection (arrows).
27. ⚠ 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 (2) to fuel filler neck. [Note: Disregard (item 1).]
28. Install rear right wheel housing liner 66.
29. Install rear seat bench 72.
30. Connect battery. Observe notes on procedures required after connecting battery 27.

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