Fuel pump, removing and installing: Installing

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Installation is the reverse of removal, noting the following:

NOTE: Secure all hose connections using hose clamps appropriate for the model type.

Insert inner part of baffle housing into outer part of baffle housing in fuel tank so the notch -1- on inner part of baffle housing aligns with marking -2- on outer part of baffle housing.
- Inner part of baffle housing can be pressed downward significantly and noticeably.

Fig 1: Notching On Inner Part Of Baffle Housing Aligns With Marking On Outer Part Of Baffle Housing

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Courtesy of AUDI OF AMERICA, INC.

Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing.

Fig 2: Inserting Fuel Pump Wrench 3307 Through Fuel Tank Opening

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Courtesy of AUDI OF AMERICA, INC.

Rotate inner part of baffle housing with pump toward right approx. 15° to stop.
- Notch -1- aligns with marking -3- (bayonet connection)

Fig 3: Notching Aligns With Marking (Bayonet Connection)

G03614439

Courtesy of AUDI OF AMERICA, INC.

Insert rigid line -3- and hose line -5- into the corresponding holes of baffle housing -6-. See Fig 4.
Press on return line -1- on union piece -4- until hose coupling engages. See Fig 4.
NOTE:
- Always use new O-rings -7- for the fuel return line.
- Coat O-rings for fuel return line with fuel or with lubricant.
Clip in rigid line -3- on union piece -4-, while doing this the union piece engages itself into baffle housing -6-. See Fig 4.

Fig 4: Inserting Rigid Line & Hose Line Into Holes Of Baffle Housing

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Courtesy of AUDI OF AMERICA, INC.

Connect harness connectors -1- and -2- for fuel gauge on inside of connector flange.

Fig 5: Connecting Harness Connectors For Fuel Gauge On Inside Of Connector Flange

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Courtesy of AUDI OF AMERICA, INC.

Insert new, dry seal for connector flange into opening of fuel tank.
When connecting the connector flange, ensure clearance of electrical wires -2- to Fuel Pump (FP) and to return hose -1-.

Fig 6: Ensuring Clearance Of Electrical Wires To Fuel Pump And To Return Hose

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Courtesy of AUDI OF AMERICA, INC.

When installing, turn connector flange in direction of arrow as shown in illustration.

Fig 7: Turning Connector Flange

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Courtesy of AUDI OF AMERICA, INC.

Insert connector flange in fuel tank, note installation position:
- Marking on connector flange -1- must align with marking on fuel tank -2-.
NOTE: Arrow points in direction of travel.

Fig 8: Marking On Connector Flange Must Align With Marking On Fuel Tank

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Courtesy of AUDI OF AMERICA, INC.

Tighten locking ring.

Fig 9: Locating Locking Ring

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Courtesy of AUDI OF AMERICA, INC.

Install supply and return hose according to marking.
Install cover for connector flange so that the protrusion lies over the harness connector.
Insert sensor 3 -item 2- in fuel tank as depicted in illustration.
- Floater -1- faces front left
NOTE:
- Arrow points in direction of travel.
- Fuel tank is depicted as cut-out section.

Fig 10: Inserting Sensor 3 In Fuel Tank

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Courtesy of AUDI OF AMERICA, INC.

When sliding in, turn sensor clockwise around its own axis (arrow).
NOTE: Do not bend floater arm of sender for fuel gauge when installing.

Fig 11: Turning Sensor Clockwise Around Its Own Axis
Courtesy of AUDI OF AMERICA, INC.

Sensor 3 is properly inserted when:
- Floater -1- and arm -2- of sensor face front left
Fig 12: Inserting Floater And Arm Of Sensor Face Front Left
Courtesy of AUDI OF AMERICA, INC.
NOTE:
- Arrow points in direction of travel.
- Fuel tank is depicted as cut-out section.
Slide new seal for fuel level sensor 3 over connector flange of sensor.
Insert dry seal into opening of fuel tank.
Check the installation position of fuel level sensor 3.
- Marking on sensor -2- must align with marking on fuel tank -1-
NOTE: Arrow points in direction of travel.

Fig 13: Checking Installation Position Of Fuel Level Sensor 3

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Courtesy of AUDI OF AMERICA, INC.

Tighten union nut for fuel level sensor 3.

Fig 14: Locating Union Nut For Fuel Level Sensor 3
Courtesy of AUDI OF AMERICA, INC.
NOTE:
- Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is re-connected.
- Deactivate service mode of Telematics Control Module.
  See TELEMATICS, ON BOARD DIAGNOSTIC (OBD) .
- Generate readiness code. See READINESS CODE, GENERATING .