Fuel Delivery Unit

Special tools and workshop equipment required

Wrench T10202

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

TT Roadster:

CAUTION:

It is necessary to remove the fuel tank first in order to be able to remove the fuel delivery unit on the Audi TT Roadster.

-- Removing fuel tank, refer to FUEL TANK WITH ATTACHMENTS .

TT Coupe:

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe measures for disconnecting battery.

-- Disconnect the battery. Refer to [For transmission(s) 02E] Removal and Installation .

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of ³ /₄ full.

-- Empty fuel tank if necessary. Refer to FUEL TANK, DRAINING .

-- Remove rear seat bench. Refer to Removal and Installation .

Fig 1: Identifying Cover From Fuel Delivery Unit

Courtesy of AUDI OF AMERICA, LLC

-- Unclip the retainers -arrows- of the cover for sealing flange.

-- Disconnect the connector -arrow- from the locking flange.

Fig 2: Identifying Fuel Delivery Unit Connector

Courtesy of AUDI OF AMERICA, LLC

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

Fig 3: Fuel Supply And Return Lines

Courtesy of AUDI OF AMERICA, LLC

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.

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

TT Roadster:

-- Mark the fuel supply -1- and the fuel return -2- lines on the removed fuel tank.

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

TT Coupe:

Fig 4: Identifying Locking Ring Using Wrench T10202, Removal/Installation

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of ³ /₄ full.

All vehicles:

-- Remove locking ring with T10202.

-- Remove the fuel delivery unit and seal trough the opening in the fuel tank.

NOTE:

When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-.
Be sure there is still some fuel inside the fuel delivery unit.

Installing

Tightening specification, refer to FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW .

Install in reverse order, paying attention to the following:

NOTE:

Replace seal.
When inserting fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-.

-- Install the fuel delivery unit into the fuel tank.

-- Install the new locking flange seal dry.

Fig 5: Identifying Installation Position Of Fuel Delivery Unit

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of leaking.

When inserting sealing flange, sealing ring must not be damaged or crushed.

-- Press locking flange down against spring pressure and bring it into installation position.

The tab -2- on locking flange must lie between tabs -1 and 3- on fuel tank.

NOTE:

-Arrow- points in direction of travel.

-- Tighten locking ring.

Fig 6: Identifying Locking Ring Using Wrench T10202, Removal/Installation

Courtesy of AUDI OF AMERICA, LLC

TT Coupe:

-- Install rear seat bench. Refer to Removal and Installation .

-- Connect the battery. Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

TT Roadster:

-- Installing fuel tank. Refer to Installing .

All Vehicles:

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

-- On vehicles with TFSI engine, with toothed belt drive, a fuel pump adaptation must be performed after replacing the fuel delivery unit. Refer to TOOTHED BELT DRIVE, PERFORMING A FUEL PUMP ADAPTATION AFTER REPLACING FUEL DELIVERY UNIT .