Fuel Pump Control Module - J538-, REMOVING AND INSTALLING, VEHICLES WITH FWD AND AWD: Removing

WARNING: This page is about a different variant/trim than selected.

-- 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 coming out of the Fuel Pump Control Module - J538- when removing, 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 .

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

Fig 1: Identifying Cover Bolts For Locking Flange

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-- Remove the locking flange cover -arrows-.

A5 from MY 2011, A4 from MY 2012:

Fig 2: Disconnect Connectors

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

-- 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 -arrow A- and squeeze the release -arrow B-.

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

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Fig 4: Connect Fuel Lines -1 And 2-

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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 .

A5 from MY 2012, A4 from MY 2013:

Fig 5: View Of Fuel Delivery Unit Harness Connectors

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-- Disconnect the connector -2- to the auxiliary heater metering pump at the locking flange, if necessary.

-- Open the connector locking mechanism with the Elbow Assembly Tool:T10118 and disconnect the connectors -1 and 3- on the locking flange.

Fig 6: View Of Fuel Delivery Unit Fuel Line Connectors

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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 .

Continuation for All Vehicles

Fig 7: Disconnecting Fuel Line To Auxiliary Heater Metering Pump At Locking Flange By Pressing Release Button

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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 Fuel Tank Sender Unit Tool:T40068A to remove the union nut -arrow-.

NOTE:

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

-- Cover the fuel tank opening with a clean cardboard box -1- to prevent dirt from falling into it.

Fig 8: Cover The Fuel Tank Opening

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-- Remove the bolts -arrows-.

-- Remove the Fuel Pump Control Module -J538- -1- toward the inside between the fuel tank and the underbody.

Fig 9: FP Control Module

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-- Disconnect the connector and remove the fuel pump control module.