Fuel delivery unit, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Observe safety precautions → Safety precautions when working on fuel supply system .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of ¹ /₄ . Drain fuel tank if necessary. Procedure → Fuel tank, draining .
Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

Fig 1: Pushing Cover Over Battery Toward Right And Removing It Upward

GW00018536

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 2: Locating Battery Ground Strap

GW00018537

Courtesy of VOLKSWAGEN UNITED STATES, INC.

With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
Open fuel filler flap briefly and then close again.
Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 3: Removing Cover Bolts For Locking Flange

GW00014428

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt cover for right locking flange - arrows -.

Fig 4: Identifying Right Locking Flange Electrical Harness Connectors

GW00018595

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 1 - at right locking flange.
Disengage electrical harness connector - 2 - and lay it aside.

CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Fig 5: Identifying Fuel Line & Ventilation Line

GW00018596

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel line - 1 - from locking flange by pressing release button.
Disconnect ventilation line - 2 - by pressing release buttons.

CAUTION: Locking flange may only be opened when fuel tank is maximum ¹ /₄ full. Otherwise, a large amount of fuel will spill out.

Fig 6: Removing/Installing Locking Ring With Wrench T10202

GW00018589

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove locking ring using wrench T10202.
Pull locking flange and sealing ring from opening of fuel tank.

Fig 7: Separating Electrical Connection On Inner Side Of Locking Flange

GW00018597

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connection on the inner side of the locking flange - arrow -.

NOTE:

To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

Fig 8: Guiding Fuel Pump Wrench 3307 Through Fuel Tank Opening And Placing It On Fuel Delivery Unit

GW00018610

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
Release fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward left until stop (bayonet connection).

Fig 9: Identifying Notch Aligns With Marking

GW00018611

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Notch - 1 - aligns with marking - 2 -.

Remove fuel delivery unit.

NOTE:

Be aware that fuel is still in the fuel delivery unit.