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

WARNING: This page is about a different car, the 2023 Audi SQ8, 2023 Audi RS Q8, and 2023 Audi Q8. However, it is still accessible from the selected car via links, so may be relevant.

Install in the reverse order of removal while noting the following:

NOTE:

Replace the seal after removal.

Check the fuel delivery unit for a secure fit.

-- If the vehicle has a parking heater, make sure the suction line for the parking/auxiliary heater fuel extraction is inserted correctly in the guide on the fuel delivery unit.

-- Carefully guide the fuel delivery unit into the fuel tank.

Courtesy of AUDI

-- Reach through the opening in the fuel tank and move the fuel delivery unit into its installation position.

The tab -1- on the fuel delivery unit must be in the groove on the baffle housing -2-.

-- Push the fuel delivery unit downward until it engages audibly into the catches on the baffle housing.

Courtesy of AUDI

-- Push on the fuel delivery unit again and pull on it to check if the catches -1 and 2- are engaged correctly.

-- Reach through the opening in the fuel tank and attach the suction jet line to the fuel delivery unit until it clicks into place.

NOTE:

Ignore the -arrows-.

-- Connect the connectors -1 and 2- and make sure they are securely engaged.

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-- Install a new sealing flange seal -1-. It must be dry.

Fig 1: Identifying Sealing Flange Installation Position

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When inserting the sealing flange, the seal must not be damaged or crushed.

-- Bring the sealing flange into its installation position.

The tab -2- on the sealing flange must face the hole -arrow- in the locking ring and rest between the tabs -3 and 4- on the fuel tank.

-- Firmly press on the sealing flange, position the locking ring and tighten using the Wrench - Fuel Sending Unit:T10202 .

Fig 2: Identifying Fuel Sending Unit Wrench

Courtesy of AUDI

-- Attach the fuel lines until they engage audibly.

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

-- It must be ensured that at least five liters of fuel are in the fuel tank after installing the fuel delivery unit.

NOTE:

Do not allow the fuel pump to run when the fuel tank is empty.

-- Install the support for the luggage compartment floor. Refer to OVERVIEW - LUGGAGE COMPARTMENT FLOOR .

-- Install the bench seat / single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Install the sill panels. Refer to OVERVIEW - SILL PANEL .

-- Connect the battery while following all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Vehicles with 48 V Electrical System:

-- Re-energize the 48 V system. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Continuation for All Vehicles:

-- Vehicles with parking heater: to bleed the fuel line to the metering pump, allow the parking heater to run for 10 minutes at full load.