Fuel Pump Control Module: Removing

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2010 Audi A5, and 2009 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

Proceed as follows:

-- Observe safety precautions SAFETY PRECAUTIONS .

-- Observe rules for cleanliness CLEAN WORKING CONDITIONS .

WARNING:

Danger Due To Escaping Fuel.

To Prevent Large Quantities Of Fuel From Draining From The Fuel Pump Control Module -J538- When Removing, The Fuel Tank May Only Be A Maximum Of ¹ /₄ Full.

-- Empty Fuel Tank If Necessary FUEL TANK DRAINING .

-- Move Passenger Seat All The Way Forward If Necessary.

CAUTION:

Risk Of Destroying Electrical Components When Battery Is Disconnected.

Observe Measures When Disconnecting Battery.

-- Disconnect Battery. Refer To BATTERY, DISCONNECTING AND CONNECTING .

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

Fig 1: Identifying Cover Bolts For Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- Remove Locking Flange Cover -arrows-.

-- Disconnect Electrical Connectors -1- And -2- On Locking Flange.

Fig 2: Disconnect Connectors

Courtesy of AUDI OF AMERICA, LLC

-- If Necessary, Disengage Electrical Connector -3- To Auxiliary Heater Metering Pump At Locking Flange And Lay It Aside.

WARNING:

There Is A Risk Of Injury Because The Fuel Is Under High Pressure.

To Reduce Pressure In Fuel System, Lay A Clean Cloth Around The Connector And Carefully Loosen Connector.

-- Disconnect fuel line -2- at locking flange by pressing release button.

Fig 3: Connect Fuel Lines -1 And 2-

Courtesy of AUDI OF AMERICA, LLC

-- If Necessary, Disconnect The Fuel Line -1- To The Auxiliary Heater Metering Pump At Locking Flange By Pressing Release Button.

WARNING:

Danger Due To Escaping Fuel.

To Prevent Large Quantities Of Fuel From Leaking Out Of The Locking Flange When Removing, The Fuel Tank May Only Be A Maximum Of ¹ /₄ Full.

-- Use a union nut tool:T40068 A to remove union nut -arrow-.

Fig 4: Disconnecting Fuel Line To Auxiliary Heater Metering Pump At Locking Flange By Pressing Release Button

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The Plastic Catch On The Threaded Ring Breaks Off When The Union Nut Is Loosened.

-- Cover Fuel Tank Opening With A Clean Cardboard Box -1- To Prevent Dirt From Falling Into It.

Fig 5: Cover The Fuel Tank Opening

Courtesy of AUDI OF AMERICA, LLC

-- Remove Bolts -arrows-.

-- Pull Fuel Pump Control Module -J538- -1- In Between Fuel Tank And Vehicle Underbody.

Fig 6: FP Control Module

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect Electrical Connector And Remove Fuel Pump Control Module.