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 ³ /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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Sedan:

Remove carpeting in luggage compartment.
Fold forward right rear seat backrest, if necessary.

Wagon:

Remove left 1/3 backrest →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.
Remove left side luggage compartment trim and dirt tray →
- 70 - INTERIOR TRIM
- 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
.

All models:

Fig 3: Unbolting Cover For Locking Flange In Luggage Compartment

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt locking flange cover in luggage compartment - arrows -.

Fig 4: Identifying Locking Flange Electrical Harness Connectors

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

Fig 5: Identifying Fuel Return Line & Fuel Return Line

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

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

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

Vehicles with 1.8L Turbo engine:

Also separate ventilation line to fuel filter at locking flange, by pressing release buttons.

All models:

CAUTION: Fuel delivery unit may only be removed when fuel tank is maximum ³ /₄ filled. Otherwise, a large amount of fuel will spill out.

Fig 6: Removing/Installing Union Nut Using Ring Nut Wrench 3217

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove union nut using Ring nut wrench 3217.

Fig 7: Lifting Fuel Delivery Unit Slightly Out Of Fuel Tank Opening And Removing Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lift fuel delivery unit slightly out of fuel tank opening and remove seal.
If fuel delivery unit is still inserted in fuel tank, slide locking flange slightly to side.
Reach through gap between locking flange and installation opening in fuel tank and release suction jet pump - 1 -.

NOTE:

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

Fig 8: Identifying Suction Jet Pump & Suction Jet Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lift suction jet pump - 1 - upward with suction jet pipe - 2 - still connected.
Disconnect suction jet line from suction jet pump by pressing release button.
Remove suction jet pump.
Remove fuel delivery unit.

NOTE:

When removing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor G.
Be aware that fuel is still in the fuel delivery unit.