Fuel Delivery Unit, Removing And Installing (A5 Through My 2011, A4 Through My 2012, Vehicles With Fwd And AWD): Installing

Install in reverse order of removal. Note the following:

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

-- Guide the suction line -3- out of the fuel tank and connect it until it engages audibly.

-- Connect the connector -2- for the Fuel Level Sensor 2 -G169-.

-- Make sure the Ground (GND) wire -arrow- is connected securely to the fuel pressure regulator retaining plate.

Fig 1: Identifying Fuel Filter

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-- Insert the Fuel Level Sensor -G- -3- into the fuel tank.

Fig 2: Insert fuel level sensor in fuel tank

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-- Pull the locking flange -2- with fuel filter away from the fuel delivery unit -1- slightly again in direction of -arrow A-.

-- Bend the fuel delivery unit to the left side of the vehicle and tilt it into the fuel tank in direction of -arrow B- while being careful of the fuel level sensor -3-.

-- Pull the locking flange -2- with the fuel filter away from the fuel delivery unit slightly in direction of -arrow A-.

Fig 3: Tilt Locking Flange With Fuel Filter Into Fuel Tank

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-- At the same time, tilt the locking flange with fuel filter into the fuel tank in direction of -B arrows-, being especially careful of the retaining plate with the GND connection -3- and the fuel line -4-.

-- Stretch the new sealing ring -1- 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 in direction of -arrow-.

Fig 4: 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 in direction of -arrow-.

Fig 5: 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 6: 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 7: Press the locking flange down firmly when tightening the union nut so it does not rotate too

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-- 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 8: 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 9: Connect Fuel Lines -1 And 2-

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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).