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

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-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of ¹ /₄ full.

-- Empty the fuel tank if necessary. Refer to FUEL TANK, DRAINING, VEHICLES WITH FWD AND AWD .

-- Move the passenger seat all the way forward if necessary.

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the 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 the locking flange cover -arrows-.

-- If equipped, disengage the connector -3- to the parking heater metering pump at the locking flange and move it to the side.

Fig 2: Disconnect Connectors

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-- Open the connector locking mechanism with the Elbow Assembly Tool T10118 and disconnect the connector -2- on the locking flange.

-- Disconnect the connector -1- on the sealing flange.

-- Push the circlip -1- upward in direction of -arrow A- and squeeze the release in direction of -arrow B-.

Fig 3: Pulling Lock -1- Upward -Arrow A- & Press -Arrow B-

Courtesy of AUDI OF AMERICA, LLC

Fig 4: Connect Fuel Lines -1 And 2-

Courtesy of AUDI OF AMERICA, LLC

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.

-- Remove the fuel line -2- from the locking flange. Refer to CONNECTOR COUPLINGS, SEPARATING .

-- Disconnect the fuel line -1- to the auxiliary heater metering pump at the locking flange, if necessary. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 5: Removing Union Nut Using Fuel Tank Sender Unit Tool T40068A

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of ¹ /₄ full.

-- Use a Fuel Tank Sender Unit Tool T40068A to remove the union nut in direction of -arrow-.

NOTE:

When union nut is loosened, plastic catch on threaded ring breaks off - ignore.

-- Remove the locking flange -2- with fuel filter from the fuel tank and tip it slightly to the left side of the vehicle.

Fig 6: Identifying Locking Flange -2- With Fuel Filter Removed From Fuel Tank And Tipped Slightly To Left Side Of Vehicle

Courtesy of AUDI OF AMERICA, LLC

-- Remove the seal -1-.

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

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

Fig 7: At Same Time, Tilt Locking Flange With Fuel Filter Out Of Fuel Tank

Courtesy of AUDI OF AMERICA, LLC

WARNING:

There is a risk of fuel leaking out from the filled fuel delivery unit.

Lay cloths below to catch the leaking fuel.

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

-- Tilt the fuel delivery unit to the left side of the vehicle in direction of -arrow B- and pull it out of the fuel tank slightly.

NOTE:

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

-- Remove the Fuel Level Sensor -G- -1- from the fuel tank opening.

-- Disconnect the intake line -3-. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 8: Pressing Release -Arrow- To Disconnect Electrical Connector -2- For Fuel Level Sensor 2 -G169-

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -2- for the Fuel Level Sensor 2 -G169- by pressing the release -arrow-.

NOTE:

The illustration shows the fuel delivery unit with the fuel tank.