Fuel Pump Control Module -J538-, REMOVING AND INSTALLING, REST OF WORLD VEHICLES WITH FWD: Removing

WARNING: This page does not describe the selected car, but rather 16 other vehicles, including the 2016 Audi S4, 2016 Audi A4 Quattro, 2016 Audi A4, 2015 Audi S4, and 2015 Audi A4 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

-- 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 coming out of the Fuel Pump Control Module - J538- when removing, fuel tank may only be a maximum of ¹ /₄ full.

-- If required, empty the fuel tank. Refer to FUEL TANK, DRAINING, REST OF WORLD VEHICLES WITH FWD .

-- 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 .

Fig 1: Identifying Cover Bolts For Locking Flange

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-- Remove the locking flange cover -arrows-.

A5 from MY 2011, A4 from MY 2012:

Fig 2: Identifying Locking Flange Components

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

-- Disconnect the connector -1- on the sealing flange.

-- Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

Fig 3: Pulling Lock -1- Upward -Arrow A- & Press -Arrow B-

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Fig 4: Connect Fuel Lines -1 And 2-

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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 .

A5 from MY 2012, A4 from MY 2013:

Fig 5: View Of Fuel Delivery Unit Harness Connectors

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

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

Fig 6: 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 .

Continuation for all vehicles:

Fig 7: Removing Union Nut Using Fuel Tank Sender Unit Tool T40068A

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WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking out of the locking flange 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 -arrow-.

NOTE:

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

-- Cover the fuel tank opening with a clean cardboard box -1- to prevent dirt from falling into it.

Fig 8: Cover The Fuel Tank Opening

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-- Remove the bolts -arrows-.

-- Remove the Fuel Pump Control Module -J538- -item 1- toward the inside between the fuel tank and the underbody.

Fig 9: Fuel Pump Control Module

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-- Disconnect the connector and remove the fuel pump control module.