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

Install in reverse order of removal. Note the following:

-- Route the ground cable as illustrated.

Fig 1: Connecting Ground Wire To Locking Flange And Fuel Pressure Regulator

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1. Locking Flange
2. Ground Cable to Locking Flange
3. Fuel Pressure Regulator
4. Ground Cable to Fuel Pressure Regulator

Make sure the fuel supply hoses are routed correctly:

Fig 2: Identifying Fuel Supply Hoses

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• The fuel supply hose must be routed outside around the guide tube.

-- Insert the guide tubes -3 and 6- with the pressure spring -5- from the sealing flange -4- in the fuel delivery unit guides -1-.

-- If the vehicle has a parking heater, make sure the intake line -2- to the metering pump is connected securely in the guide on the fuel delivery unit.

-- Guide the Fuel Level Sensor 2 -G169- wire out of the fuel tank.

Fig 3: Identifying Fuel Level Sensor -G-

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-- Carefully install the fuel delivery unit and Fuel Level Sensor -G- back into the fuel tank.

-- Make sure the Fuel Level Sensor 2 -G169- wire is installed correctly:

• Guide the Fuel Level Sensor 2 -G169- wire -5- between the guide tubes -2- and -3- and the fuel pressure regulator -4-.
• Guide the wire -5- over the supply hose -1- and behind the wire -6- for the Fuel Level Sensor -G- and -7- for the Transfer Fuel Pump -G6-.

Audi RS6/RS7: 

Fig 4: Identifying Suction Jet Pipe

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-- Carefully guide the suction jet pump into the fuel tank.

-- Reach through the opening in the fuel tank and clip the suction jet pump -1- onto the fuel delivery unit. The suction jet pump must audibly latch.

-- Install the suction jet pipe -2- until it engages audibly.

Continuation for All Vehicles: 

Fig 5: Identifying Connector

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-- Connect the connector -2- for the Fuel Level Sensor 2 -G169- to the locking flange -1- and make sure it is locked secure.

-- Carefully guide the fuel supply line from the Transfer Fuel Pump -G6- to the fuel pressure regulator in the fuel tank.

Verification: 

Fig 6: Locking Flange Guide Pipes -2- And -3-

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• The locking flange guide pipes -2- and -3- must be inserted into the guides on the fuel delivery unit.
• Vehicles with parking heater: The intake line -1- to the metering pump must be inserted into the guide on the fuel delivery unit.

-- Install a new dry locking flange seal -4-.

Fig 7: Identifying Dry Locking Flange Seal -4-

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-- Press the locking flange downward against the spring force and move it into its installed position.

• The tab -1- on the locking flange must face the hole -arrow- in the retaining ring and between the tabs -2 and 3- on the fuel tank.

-- Attach the fuel lines so that they audibly latch.

-- Connect the connectors and make sure they are secure.

-- Install the right locking 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, DISCONNECTING AND CONNECTING .

-- After installing the fuel delivery unit, at least 5 liters (5.28 quarts) of fuel must be added before starting the engine.

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