Fuel Delivery Unit, Removing And Installing (A5 From My 2012, A4 From My 2013, Vehicles With Fwd And AWD): Installing

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Install in reverse order of removal. Note the following:

Tightening specification. Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

NOTE:

Replace the sealing ring and the union nut.

Be careful not to bend the floater arm on the Fuel Level Sensor -G- when installing the fuel delivery unit.

Make sure the fuel hoses are secure.

-- Make sure the Ground (GND) wire -4- on the fuel pressure regulator and the sealing flange is securely attached -arrows-.

Fig 1: Fuel Delivery Unit Connector

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-- Make sure the following connectors are secure:

The connectors -1, 2 and 3- must be connected securely to the locking flange.

-- Pull on the connector to make sure it is locked secure.

-- Insert the fuel gauge/fuel delivery unit in the fuel tank.

-- Stretch the new sealing ring over the locking flange and insert it in the groove on the fuel tank.

-- Place the union nut -1- on your left arm and push the locking flange -2- forcefully into installation position with your left hand -arrow-.

Fig 2: Place Union Nut On Your Left Arm And Push Locking Flange Forcefully Into Installation Position With Your Left Hand

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The tab -4- on locking flange must be between the tabs -3 and 5- on the 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 3: Press Locking Flange Down Firmly

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-- Position the union nut -1- with your right hand so the double ridge -5- on the ribs is over the lug -3- on the locking flange (approximately "10 o'clock" position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it -4-.

-- Press the locking flange down firmly in direction of -arrow-.

Fig 4: Turn Union Nut Approximately 480Degrees With Your Right Hand

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-- Turn the union nut approximately 480° with your right hand until the double ridge -1- is in approximately "2 o'clock position" while keeping the locking flange pressed down firmly with your left hand.

Fig 5: Press the locking flange down firmly when tightening the union nut so it does not rotate too

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CAUTION:

There is a risk of the locking flange threaded connection leaking.

Press the locking flange down firmly when tightening the union nut so it does not rotate too.

-- Tighten the union nut using Fuel Tank Sender Unit Tool T40068A.

Check: The double ridge -1- must now be between "7 and 8 o'clock".

Fig 6: Double Ridge -1- Must Now Be Between "7 And 8 O'clock"
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-- Install the fuel lines -1 and 2- until they click into place.

Fig 7: View Of Fuel Delivery Unit Fuel Line Connectors

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-- Press the fuel line on again and pull to make sure the connection is engaged correctly.

-- Connect the connectors.

-- Install the sealing flange cover. Refer to Figure.

-- Install the rear bench seat. Refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

-- Connect the battery while doing so, follow all steps after connecting the battery. Refer to BATTERY CONNECTING .

-- After installing fuel delivery unit, fill vehicle with at least 5 liters (5.28 qts) of fuel.

-- Vehicles with auxiliary heater: To vent the fuel line to the auxiliary heater metering pump, run for 10 minutes at wide open throttle (WOT).

Fig 8: Identifying Cover Bolts For Locking Flange

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