Fuel Delivery Unit: Removing

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2010 Audi A5, and 2009 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

Proceed As Follows:

-- Observe Safety Precautions SAFETY PRECAUTIONS .

-- Observe Rules For Cleanliness 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 Fuel Tank If Necessary FUEL TANK DRAINING .

-- Move Passenger Seat All The Way Forward If Necessary.

CAUTION:

Risk Of Destroying Electrical Components When Battery Is Disconnected.

Observe Measures When Disconnecting Battery.

-- Disconnect Battery. Refer To BATTERY, DISCONNECTING AND CONNECTING .

-- Remove Rear Bench Seat. Refer To SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

-- Remove Locking Flange Cover -arrows-.

Fig 1: Identifying Cover Bolts For Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect Electrical Connectors -1- And -2- On Locking Flange.

Fig 2: Disconnect Connectors

Courtesy of AUDI OF AMERICA, LLC

-- If Necessary, Disengage Electrical Connector -3- To Auxiliary Heater Metering Pump At Locking Flange And Lay It Aside.

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.

-- Disconnect Fuel Line -2- At Locking Flange By Pressing Release Button.

Fig 3: Connect Fuel Lines -1 And 2-

Courtesy of AUDI OF AMERICA, LLC

-- If Necessary, Disconnect Fuel Line -1- To Auxiliary Heater Metering Pump At Locking Flange By Pressing Release Button.

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 Union Nut Tool:T40068 A To Remove Union Nut -arrow-.

Disconnecting Fuel Line To Auxiliary Heater Metering Pump At Locking Flange, By Pressing The Release Button.

Fig 4: Disconnecting Fuel Line To Auxiliary Heater Metering Pump At Locking Flange By Pressing Release Button

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The Plastic Catch On Threaded Ring Breaks Off When Union Nut Is Loosened.

-- Remove Locking Flange -2- With Fuel Filter From Fuel Tank And Tip It Slightly To Left Side Of Vehicle.

Fig 5: Identifying Locking Flange -2- With Fuel Filter Removed From Fuel Tank And Tipped Slightly To Left Side Of Vehicle

Courtesy of AUDI OF AMERICA, LLC

-- Remove Seal -1-.

-- Pull Locking Flange With Fuel Filter Away From Fuel Delivery Unit Slightly -arrow A-.

-- At The Same Time, Tilt Locking Flange With Fuel Filter Out Of Fuel Tank -B arrows-, Being Especially Careful Of The Retaining Plate With Ground (Gnd) Connection -3- And The Fuel Line -4-.

Fig 6: At Same Time, Tilt Locking Flange With Fuel Filter Out Of 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 Locking Flange -2- With Fuel Filter Away From Fuel Delivery Unit -1- Slightly Again -arrow A-.

-- Tilt Fuel Delivery Unit To Left Side Of Vehicle -Arrow B- And Pull It Out Of Fuel Tank Slightly.

NOTE:

When Removing Fuel Delivery Unit, Be Sure Not To Bend Floater Arm On Fuel Level Sensor -G-.

-- Remove Fuel Level Sensor -G- -3- From Fuel Tank Opening.

-- Remove Suction Line -3- By Pressing Release -1-.

Fig 7: Pressing Release -Arrow- To Disconnect Electrical Connector -2- For Fuel Level Sensor 2 -G169-

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect Electrical Connector -2- For Fuel Level Sensor 2 -G169- By Pressing Release -arrow-.

NOTE:

The Illustration Shows The Fuel Delivery Unit With The Fuel Tank.