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.

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:

• 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.

-- 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 

-- 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 

-- 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: 

• 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-.

-- 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 Tighten The Cover Srews 1.5Nm .

-- Install the rear bench seat. Refer to REAR SEATS . .

-- Connect the batter while doing so follow all steps after connecting the battery. Refer to BATTERY . .

-- 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.