Fuel Delivery Unit, Removing And Installing (A5 From My 2012, A4 From My 2013, Vehicles With Fwd And AWD): Removing

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-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of ¹ /₄ full.

-- Empty the fuel tank if necessary. Refer to FUEL TANK, DRAINING, VEHICLES WITH FWD AND AWD .

-- Move the passenger seat all the way forward if necessary.

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the rear bench seat. Refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

-- Remove the locking flange cover -arrows-.

Fig 1: Identifying Cover Bolts For Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -2- to the auxiliary heater metering pump at the locking flange, if necessary.

Fig 2: View Of Fuel Delivery Unit Harness Connectors

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-- Open the connector locking mechanism with the Elbow Assembly Tool T10118 and disconnect the connectors -1 and 3- on the locking flange.

Fig 3: View Of Fuel Delivery Unit Fuel Line Connectors

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WARNING:

There is a risk of injury because the fuel is under high pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Remove the fuel line -2- from the locking flange. Refer to CONNECTOR COUPLINGS, SEPARATING .

-- Disconnect the fuel line -1- to the auxiliary heater metering pump at the locking flange, if necessary. Refer to CONNECTOR COUPLINGS, SEPARATING .

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of ¹ /₄ full.

-- Use a Fuel Tank Sender Unit Tool T40068A to remove the union nut in direction of -arrow-.

Fig 4: Removing Union Nut Using Fuel Tank Sender Unit Tool T40068A

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NOTE:

When union nut is loosened, plastic catch on threaded ring breaks off - ignore.

-- Pull the locking flange -2- out of the fuel tank slightly and remove the sealing ring -1-.

Fig 5: View Of Sealing Ring -1-, Locking Flange -2-, And Fuel Level Sensor Connector -3-

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-- Disconnect the connector -3- for the Fuel Level Sensor 2 -G169- by pressing the release.

Fig 6: Removing Fuel Delivery Unit From Fuel Tank

Courtesy of AUDI OF AMERICA, LLC

WARNING:

There is a risk of fuel leaking out from the filled fuel delivery unit.

Lay cloths below to catch the leaking fuel.

-- Pull the fuel delivery unit -2- out of the fuel tank slightly, tilt it toward the left side of the vehicle in direction of -arrow - and remove it.

NOTE:

Be careful not to bend the floater arm on the Fuel Level Sensor -G- when removing the fuel delivery unit.

-- Remove the Fuel Level Sensor -G- -1- from the fuel tank opening.