Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing: Removing
-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
-- Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .
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.
-- If required, empty the fuel tank. Refer to FUEL TANK, DRAINING .
-- Move the right front seat all the way forward.
Risk of damaging electronic components when disconnecting the battery.
- Complete the steps for disconnecting the battery.
-- Disconnect the ground cable from the battery terminal. Refer to BATTERY . .
-- Remove the rear bench seat. Refer to REAR SEATS . .
-- Fold the insulation mat near the locking flange cover to the side.
-- Remove the bolts -arrows- and the locking flange cover.
-- Open the connector locking mechanism with the :T10118 and disconnect the connectors -1 and 2- on the locking flange.
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.
-- Vehicles with parking heater: Disconnect the fuel line -1- to the auxiliary heater metering pump at the locking flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .
-- Remove the fuel line -2- from the locking flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .
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.
-- Remove the locking ring using the :T10202 .
-- Pull the locking flange just -1- a little out of the opening in the fuel tank and remove the seal.
-- Disconnect the connector -2-.
-- Remove the locking flange with the fuel filter and the fuel line carefully from the fuel tank opening.
Audi RS6/RS7
-- Reach through the opening in the fuel tank, release the suction jet pump -1- at the retainers in direction of -arrows- and remove it from the fuel delivery unit.
-- Press the release and disconnect the fuel line -2-.
-- Carefully remove the suction jet pump from the opening in the fuel tank.
Continuation for All Vehicles
There is a risk of fuel leaking out from the filled fuel delivery unit.
- Lay cloths below to catch the leaking fuel.
-- Carefully remove the fuel delivery unit -2- and fuel level sensor -1- through the opening in the fuel tank.
Be careful not to bend the floater arm on the Fuel Level Sensor -G- when removing the fuel delivery unit.
Disconnect the Fuel Delivery Unit and Sealing Flange:
The connecting line is only an assembly aid and it no longer needs to be installed.
-- Cut the plastic connecting line -arrow-.
-- Disconnect the connectors -2 and 3-.
-- Remove the fuel supply line -1- from the fuel pressure regulator. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .
-- Remove the locking flange from the fuel delivery unit.