Left Suction Jet Pump, Removing And Installing, Vehicles With 3.0L (V6)/4.2L (V8) Engines Through 05/2010: Installing

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Install in reverse order of removal. Note the following:

Tightening specifications, refer to OVERVIEW - FUEL DELIVERY UNIT/SUCTION JETION PUMP/FUEL LEVEL SENSOR, VEHICLES WITH 3.0L (V6)/4.2L (V8) ENGINES THROUGH 05/2010 .

NOTE:

Replace seals.

Verify that the suction jet pump is securely engaged.

-- Insert the suction jet pump into guide and press it down until it clicks into place.

-- Push the delivery line through the opening on the left side of the fuel tank and into the right fuel tank chamber.

-- Before installing, check the routing of the wires on the Fuel Level Sensor 2 -G169-.

Fig 1: Fuel Delivery Unit Tabs Location

Courtesy of AUDI OF AMERICA, LLC

-- The wire must be clipped into the tabs -arrows- as illustrated.

-- Insert the Fuel Level Sensor 2 -G169- into the guide and press it down until it clicks into place.

-- Install the left fuel delivery unit, refer to Installing .

-- Connect the delivery line -4- to the right fuel delivery unit until it clicks.

Fig 2: Fuel Lines Location

Courtesy of AUDI OF AMERICA, LLC

-- Push the fuel lines -1 and 2- onto the right locking flange until they click into place.

NOTE:

Ignore item -3-.

-- Disconnect the connector -1- from the fuel pump on the bottom side of the right locking flange.

Fig 3: Identifying Electrical Connectors -1 - And -2- On Underside Of Right Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- Wrap the wire -2- for the Fuel Level Sensor -G- twice around the wire -1- for the fuel pump and then connect it to the right locking flange.

-- Install the new seal for the right locking flange dry.

-- Bring the right locking flange into the installation position:

Fig 4: Aligning Tab -2- On Right Locking Flange Between Tabs -1- And -3-

Courtesy of AUDI OF AMERICA, LLC

Tab -2- on right locking flange faces toward arrow marking and must lie between tabs -1 and 3- on fuel tank.

-- Install the right locking flange cover, refer to Figure.

-- Insert the frame into the floor covering, refer to the Parts Catalog and Interior Trim .

-- Install the right rear single seat in the second row of seats, refer to Seat Frames .

-- Vehicles with parking heater: Bleed the fuel supply line to the metering pump, refer to FUEL SUPPLY LINE TO METERING PUMP, BLEEDING, VEHICLES WITH PARKING HEATER .

-- After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.