Fuel Pump (FP) Control Module J538 , removing and installing

Removing

Observe safety precautions → Safety precautions when working on fuel supply system .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

To lower, fuel tank must be empty for weight reasons. Drain fuel tank if necessary. Procedure → Fuel tank, draining .

CAUTION:

Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

All except Audi RS4:

Fig 1: Pushing Cover Over Battery Toward Right And Removing It Upward

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Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 2: Locating Battery Ground Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Audi RS4:

Raise luggage compartment floor covering and secure.

Fig 3: Disconnecting Battery Ground (GND) Strap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

All:

Open tank flap and clean area around fuel filler tube.

NOTE:

Do not remove fuel cap.

Fig 4: Opening Tank Flap And Cleaning Area Around Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.
Remove right rear wheel.
Remove right rear wheel housing liner →
- 66 EXTERIOR EQUIPMENT
- 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
.

Fig 5: Removing Ventilation Line From Fuel Filler Tube & Bolts For Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unfasten bolts - 1 - for fuel filler tube.

NOTE:

Ignore - 2 -.

Fig 6: Removing Right Rear Cover On Bottom Of Vehicle Floor

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Remove right rear cover - 1 - on bottom of vehicle floor.

CAUTION:

For weight reasons, fuel tank must be empty when lowering.

Fig 7: Identifying Fuel Tank Bolts

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Loosen screws - 1, 2, 3, 4, 5, 9, 10 - a maximum of 8 turns.
Remove bolts - 6, 7, 8 -.
Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 8: Removing Cover Bolts For Locking Flange

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Unbolt cover for right locking flange - arrows -.

Audi RS4:

Fig 9: Removing Electrical Wires With Connector From Locking Flange Opening

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Free up electrical connector - arrow - for Fuel Pump (FP) Control Module J538 and disconnect.

All:

Fig 10: Disconnecting Electrical Harness Connector At Right Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at locking flange.

Fig 11: Identifying Fuel Return Line And Fuel Supply Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark fuel return line - 1 - and fuel supply line - 2 -.

CAUTION: Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

Pull both lines from locking flange, by pressing release buttons.

Fig 12: Removing Bolts & Fuel Pump (FP) Control Module J538 Between Fuel Tank And Vehicle Floor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove Fuel Pump (FP) Control Module J538 between fuel tank and vehicle floor.

Installing

Installation is in reverse order of removal. Note the following:

Fig 13: Identifying Fuel Tank Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten mounting straps and carrier plate - 1 through 10 -.

Fig 14: Removing Ventilation Line From Fuel Filler Tube & Bolts For Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten fuel filler tube with Ground (GND) connection using bolt - 1 -.

CAUTION: After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:

Specification: approx. 0 Ω.

NOTE:

Ignore - 2 -.

Install right rear wheel housing liner →
- 66 EXTERIOR EQUIPMENT
- 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
.
Install rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.
Connect battery. Observe safety precautions after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

Torque specifications

Component	Nm
Mounting straps and carrier plate for fuel tank to body	23
Fuel filler tube to wheel housing	23
Fuel Pump (FP) Control Module J538 to body	2.5