Fuel Sender With Fuel Pump, Removing and Installing (AWD)

Fuel Sender With Fuel Pump, Removing And Installing

Special tools, test equipment and auxiliary items







- 3087 Wrench
- 3307 Fuel Pump Wrench
- T40020 Unlocking Tool

Removing
- For the removal of the fuel sender the fuel tank should be a maximum 1/4 full. Drain fuel tank if necessary.

CAUTION: After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar(R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

- Vehicles with coded radio/navigation system (RNS) coding, refer to the Owner's Manual, if necessary.

Audi A6:







- Remove cover above battery -arrows-.

NOTE: On vehicles without battery cover: Remove plenum cover.







- Disconnect battery Ground (GND) strap -arrow- with ignition switched off.

Audi RS6:







- Turn locks -arrow- counterclockwise and remove cover -1-
- Remove cover -1- off upward.







- With ignition switched off, disconnect battery Ground (GND) cable -arrow-.

All:
- Open fuel filler cap briefly and close again
- Remove rear seat bench.
- Remove screws -arrows- for the cover.







- Carefully release 4-pin harness connector and disconnect.

WARNING:
- Fire Hazard. Do not smoke, work near heaters or have anything in the area that could ignite the fuel or fumes.
- Fuel supply lines are under pressure. Before loosening any lines, cover the connection with a rag. Release the pressure by slowly separating the connection.







- Mark fuel supply line -1- and return line -2- and disconnect from closing flange (right side).

WARNING: The closing flange should only be opened if the fuel tank is maximum 1/4 full. Otherwise large quantities of fuel escape. Drain fuel tank if necessary.







- Remove closing ring for sender for fuel gauge using 3087 wrench.
- Remove closing flange and seal from tank opening.







- Disconnect both harness connector for fuel gauge -1- and -2- on inside of closing flange.







- Disengage distributor connector -1- at lower part of accumulator by pressing distributor connector slightly to left side of vehicle and lift upward -arrow-.
- Release return line -2- from distributor connector and disconnect.

NOTE: For better illustration purpose the accumulator is shown without fuel tank.







- In addition, unlock quick coupling line connector of return pipe with Unblocking Tool T40020.







- Insert 3307 fuel pump wrench through fuel tank opening into inner part of accumulator.
- Using 3307 fuel pump wrench, turn fuel pump module approx. 15 degrees to right (to stop).







- Notch -1- must then align with marking -2- (bayonet lock)
- Lift out fuel pump together with inner part of accumulator.

Installing
Installation is the reverse of removal, however note the following:

NOTE: Replacement hose clamps must be the same type of clamp that was used in production







- Install fuel pump module into tank with notch -1- on fuel pump module lining up with marking -2- on outside of fuel pump module.
- It should feel that it is possible to press fuel pump module down.







- Insert 3307 Fuel Pump Wrench through fuel tank opening and place on accumulator.







- Using 3307 fuel pump wrench, turn fuel pump module approx. 15 degrees to right (to stop).
- Notch -1- must then align with marking -3-.

- Insert solid line -3- and hose -5- in relevant openings of accumulator -6-.







- Push return line -1- onto distributor connector -4- until hose coupling engages.

NOTE:
- Always use new O-rings -7- for the return line.
- Lubricate O-rings for return line with fuel or lubricant.

- Clip solid line -3- into distributor connector -4- while distributor locks into accumulator -6-.







- Reconnect harness connectors -1- and -2- for fuel gauge to inside of closing flange.
- Insert new seal for closing flange dry into fuel tank opening.







- Ensure that wiring for fuel pump -2- and fuel return line -1- is correctly routed when installing closing flange.







- When installing, turn closing flange in direction of arrow, as shown in illustration.







- Install closing flange into tank opening. Note installation position:
- Marking on closing flange -1- must align with marking -2- on fuel tank.

NOTE: The -arrow- points toward the front of the vehicle.







- Tighten closing ring with 120 Nm (89 ft lb).
- Install fuel supply and return lines as previously marked.
- Install cover for closing flange with indentation over connector.

NOTE: With Battery re-connected, remember to activate electrical equipment (radio, clock, window switches) according to operating instructions.

- Generate readiness code.

Tightening torque

Component Tightening torque
Closing ring for fuel pump delivery module 145 Nm (106 ft lb)
Battery connections 5 Nm (44 in. lb)