Fuel delivery unit, removing and installing: Installing

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.

Installation is in reverse order of removal. Note the following:

NOTE:

Replace seal.
When installing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G.
Make sure fuel hose is seated securely.

Insert fuel delivery unit into fuel tank.

Fig 1: Identifying Suction Jet Pump & Suction Jet Pipe

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Connect suction jet line - 2 - to connection for suction jet pump - 1 -.

Fig 2: Lifting Fuel Delivery Unit Slightly Out Of Fuel Tank Opening And Removing Seal

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Clip in suction jet pump - 1 - on fuel delivery unit. To do so, insert hand into gap between locking flange and installation opening of fuel tank.

Suction jet pump must engage audibly.

Verify that the suction jet pump is securely engaged.

NOTE:

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

Fig 3: Identifying Marking On Locking Flange Align With Marking On Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install new locking flange seal dry.
Press locking flange down against spring pressure and bring it into installation position.

Marking - 2 - on locking flange must align with marking - 1 - on fuel tank.

Fig 4: Removing/Installing Union Nut Using Ring Nut Wrench 3217

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Tighten union nut for locking flange.

Fig 5: Identifying Fuel Return Line & Fuel Return Line

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Install fuel supply line - 1 - and fuel return line - 2 - according to marking.

Vehicles with 1.8L Turbo engine:

Also, install ventilation line to fuel filter at locking flange.

All models:

Connect electrical harness connector.
Connect battery. Observe safety precautions after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
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