Fuel delivery unit, removing and installing: Removing

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

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of ¹ /₄ . Drain fuel tank if necessary. Procedure → Fuel tank, draining .
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

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

All:

Open fuel filler flap briefly and then close again.
Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 4: Removing Cover Bolts For Locking Flange

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Unbolt cover for right locking flange - arrows -.

Audi RS4:

Fig 5: 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 6: Disconnecting Electrical Harness Connector At Right Locking Flange

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Disconnect electrical harness connector - arrow - at right locking flange.

Fig 7: Identifying Fuel Return Line And Fuel Supply Line

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

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

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

CAUTION: Locking flange may only be opened when fuel tank is maximum ¹ /₄ full. Otherwise, a large amount of fuel will spill out.

Fig 8: Removing/Installing Locking Ring With Wrench T10202

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Remove locking ring using wrench T10202.
Remove locking flange and seal from opening in fuel tank and lay aside locking flange with lines still connected.

Fig 9: Identifying Suction Jet Pipe & Fuel Delivery Line

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Disconnect suction jet pipe - 1 - to suction jet pump by pressing release button.
Disengage fuel delivery line - 2 -.
Remove fuel delivery unit.

NOTE:

When removing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor G.
Be aware that fuel is still in the fuel delivery unit.