Fuel Pump Control Module: Installing

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Tightening Specifications FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW .

Installation Is In Reverse Order Of Removal, Note The Following:

NOTE:

Replace sealing ring and union nut.

-- Bring Fuel Pump Control Module -J538- Into Installation Position And Tighten It.

-- Place Union Nut -1- On Your Left Arm And Push Locking Flange -2- Forcefully Into Installation Position With Your Left Hand -arrow-.

Fig 1: Place Union Nut On Your Left Arm And Push Locking Flange Forcefully Into Installation Position With Your Left Hand

Courtesy of AUDI OF AMERICA, LLC

The Tab -4- On Locking Flange Must Lie Between Tabs -3- And -5- On Threaded Ring.

-- Slide The Union Nut -1- Off Your Left Arm Using Your Right Hand While Your Left Hand Keeps Holding The Locking Flange -2- Down Firmly -arrow-.

Fig 2: Press Locking Flange Down Firmly

Courtesy of AUDI OF AMERICA, LLC

-- Position Union Nut -1- With Your Right Hand So The Double Ridge -5- On Ribs Is Over Lug -3- On Locking Flange (Approximately "10 O'clock" Position). This Makes Sure Union Nut Engages At Beginning Of Threads Immediately When Tightening It -4-.

-- Press Locking Flange Down Firmly With A Screwdriver -arrow-.

-- Turn Union Nut Approximately 480° With Your Right Hand Until Double Ridge -1- Is In Approximately "2 O'clock Position" While Keeping Locking Flange Pressed Down Firmly With Your Left Hand.

Fig 3: Turn Union Nut Approximately 480 Degrees With Your Right Hand

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

There Is A Risk Of The Locking Flange Threaded Connection Leaking.

Press Locking Flange Down Firmly When Tightening The Union Nut So It Does Not Rotate Too.

-- Tighten Union Nut Using A Union Nut Tool:T40068 A .

Press The Locking Flange Down Firmly When Tightening The Union Nut So It Does Not Rotate Too.

Fig 4: Press The Locking Flange Down Firmly When Tightening The Union Nut So It Does Not Rotate Too

Courtesy of AUDI OF AMERICA, LLC

Verification: The Double Ridge -1- Must Now Be Between "7 And 8 O'clock".

Fig 5: Double Ridge -1- Must Now Be Between "7 And 8 O'clock"
Courtesy of AUDI OF AMERICA, LLC

-- Connect Fuel Lines -1- And -2-.

Fig 6: Connect Fuel Lines -1 And 2-

Courtesy of AUDI OF AMERICA, LLC

-- Connect Electrical Connectors.

-- Install Right Locking Flange Cover.

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

-- Connect Battery And Observe Safety Precautions After Connecting Battery. Refer To BATTERY, DISCONNECTING AND CONNECTING .

-- To Vent Fuel Line To Auxiliary Heater Metering Pump, Run For 10 Minutes At Wide Open Throttle (WOT).