Fuel delivery unit and Fuel level sensor, assembly overview

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.

Fig 1: Fuel Delivery Unit And Fuel Level Sensor, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Fuel Level Sensor G

Resistance values, checking → Fuel Level Sensor G , testing
Removing and installing → Fuel Level Sensor G , removing and installing

2 - Fuel delivery unit

Fuel pump electrical, checking → Fuel pump electrical, checking
Checking residual pressure →
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- 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
- 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH
- 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS
- 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF
Removing and installing → Fuel delivery unit, removing and installing

3 - Oil seal

Replace
Install dry

4 - Fuel return line

From fuel filter
Mark before removing
To disconnect, press release button on connection piece
Do not kink

Note direction of arrow (fuel supply or return) on locking flange when installing
Clipped in on fuel tank

5 - Ventilation line

From fuel pressure regulator in fuel filter
To disconnect, press release button on connection piece
Do not kink
Clipped in on fuel tank

6 - Fuel supply line

To fuel filter
Mark before removing
To disconnect, press release button on connection piece
Do not kink

Note direction of arrow (fuel supply or return) on locking flange when installing
Clipped in on fuel tank

7 - Electrical harness connector

For Fuel level sensor G
For Transfer Fuel Pump (FP) G6

8 - Locking ring

Use wrench T10202 to remove and install
Tighten to 145 Nm

9 - Suction jet pipe

To disconnect, press release button on connection piece

10 - Suction jet pump