Fuel Supply Unit, Removing and Installing
Observe Safety precautions Technician Safety Information
Observe Rules of cleanliness Vehicle Damage Warnings
Required special tools, testing equipment and auxiliary equipment
- FM 3000 Fuel cart (or equivalent)
- 3217 Union nut wrench
- 3307 Fuel pump wrench
- VAG1275 Hose clamp pliers
Removing
CAUTION! Obtain the radio Anti-theft code from the customer before disconnecting the Battery Ground strap.
- Disconnect Battery Ground strap with ignition switched OFF.
- Open fuel tank cover briefly and close again.
- If necessary, drain fuel tank using fuel cart. Service and Repair
NOTE: The fuel tank must not be filled to more than 1/3 maximum.
- Remove connector flange cover under luggage compartment trim.
WARNING! Fuel system is under pressure! Before opening, place clean cloths around the connections to be opened. Carefully loosen the connections to relieve pressure.
- Mark return line -2- and supply line -3- and disconnect from cover flange.
- Unlatch and disconnect 4-pin harness connector -1-.
- Unscrew union nut using 3217 wrench .
- Remove cover flange and sealing ring from fuel tank opening.
- Disconnect fuel level display harness connector on inside of flange cover.
- Disconnect return line on inside of cover flange (press unlatching buttons).
- Insert 3307 wrench through fuel tank opening and place over the inner section of the surge housing.
- Using 3307 wrench, turn inner section of surge housing approx. 15° to the left up to the stop and withdraw fuel pump assembly complete with the inner housing section.
Cover flange and surge housing inner section, pre-assembling
If cover flange and supply unit were separated
- Pre-assemble parts Fuel Supply Unit and Fuel Level Sensor, Component Overview
- Angle position, cover flange to inner section of surge housing: 10°
- Press together clamps for supply line (between pump and cover flange) with VAG1275 pliers.
- Attach wiring to fuel pump.
- M4: 1.5 Nm (13 in. lb)
- M5: 2 Nm (18 in. lb)
NOTE: Install a toothed washer beneath each nut.
- Attach wiring with fuel-resistant cable ties.
Installing
Installation is performed in the reverse of removal, when installing, note the following:
CAUTION! Always refer to the latest parts catalog or contact your Audi Dealer Parts Department to ensure that you use original equipment fuel hose clamps.
- Install surge housing inner section, supply hose and cover flange in the fuel tank.
- Place inner section of surge housing into outer section of surge housing in tank such that notch -1- on inner section of surge housing matches mark -2- on outer section of surge housing.
- The inner section of the surge housing can be audibly pressed downward.
- Attach 3307 pump wrench and turn surge housing inner section to the right approx. 15° (up to the stop).
- Notch -1- will then be in front of mark -3- (bayonet closure)
NOTE: For clarity, the surge housing outer and inner sections are shown in the illustration without the fuel tank.
- When installing, turn cover flange in direction of arrow to the right as shown in the illustration.
- Connect the return line inside on the cover flange.
NOTES:
- Always use new O-rings.
- Lubricate O-rings with fuel or coat with lubricant.
- Install new cover flange gasket (dry) in Fuel tank opening.
- Wrap fuel level sensor wire once around the supply line (in fuel tank) and install on cover flange.
- Attach cover flange to fuel tank
- Vehicles with all wheel drive: arrow 1 must be opposite arrow 2
NOTE: -Arrow 3- only applies to vehicles with Front-wheel drive.
- Tighten union nut with 3217 wrench.
- 60 Nm (44 ft lb)
- Connect wiring and harness connector.
NOTE: Ensure that fuel hoses fit tightly.
- Connect Battery Ground strap with ignition switched OFF.
- After connecting Battery, input radio anti-theft code
- Run door windows up to stop using electric window lifters.
- Operate all window lifters again for at least 1 second in "closed" position to activate automatic up/down.
- Set the clock.