Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing: Removing

WARNING: This page is about a different car, the 2016 Audi Q5, 2015 Audi Q5, and 2014 Audi Q5. However, it is still accessible from the selected car via links, so may be relevant.

-- Follow all safety precautions, refer to FUEL SYSTEM SAFETY PRECAUTIONS .

-- Follow the rules for clean working conditions, refer to 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 ³ /₄ full.

-- If required, empty the fuel tank, refer to FUEL TANK, DRAINING .

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

-- Remove 1/3 of the rear seat, refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

Fig 1: Identifying Locking Flange Cover & Bolts -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- and remove the sealing flange cover -1-.

Fig 2: Harness Connectors -1- & -2- At Sealing Flange

Courtesy of AUDI OF AMERICA, LLC

-- Open the connector locking mechanism with the Elbow Assembly Tool T10118 and disconnect the connector -1- on the sealing flange.

-- Disconnect the connector -2- 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

WARNING:

Very hot fuel can burn your skin.

In extreme cases the temperature of the fuel lines and/or the fuel can go up to 100 °C (212 °F). Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves.
Wear protective eyewear.

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.

-- Press the release button and disconnect the fuel lines -1- and -2- from the locking flange.

-- Press the release button and disconnect the metering pump fuel line -3- on the sealing flange for vehicles with an auxiliary heater.

Fig 4: Identifying Fuel Lines At Sealing Flange

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 ³ /₄ full.

-- Remove locking ring using the Wrench - Fuel Sending Unit T10202.

Fig 5: Identifying Locking Ring Using Wrench T10202, Removal/Installation

Courtesy of AUDI OF AMERICA, LLC

-- Remove the locking flange -3- from the fuel tank and remove the seal -1-.

WARNING:

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

Lay cloths below to catch the leaking fuel.

NOTE:

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

-- Pull the fuel delivery unit -2- out of the fuel tank slightly, tilt it toward the right side of the vehicle arrow and remove it.

Fig 6: Removing Fuel Delivery Unit From Fuel Tank

Courtesy of AUDI OF AMERICA, LLC