Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

Follow all safety precautions. Refer to => [ Safety Precautions ] General Information.

Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

TT Roadster:

• It is necessary to remove the fuel tank first in order to be able to remove the fuel delivery unit on the Audi TT Roadster.

- Removing fuel tank, refer to => [ Fuel Tank with Attachments ] Fuel Tank with Attachments.

TT Coupe:

Risk of destroying electronic components when disconnecting the battery.

• Observe measures for disconnecting battery.

- Disconnect the battery.

Danger due to escaping fuel.

• To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 3/4 full.

- Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Remove rear seat bench.






- Unclip the retainers - arrows - of the cover for sealing flange.

- Disconnect the connector - arrow - from the locking flange.






- Mark the fuel supply line - 1 - and fuel return line - 2 -.






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.

- Pull both lines from locking flange, by pressing the release buttons.

TT Roadster:

- Mark the fuel supply - 1 - and the fuel return - 2 - lines on the removed fuel tank.

- Pull both lines from locking flange, by pressing the release buttons.

TT Coupe:






Danger due to escaping fuel.

• To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 3/4 full.

All vehicles:

- Remove locking ring with (T10202).

- Remove the fuel delivery unit and seal trough the opening in the fuel tank.

• When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor (G).

• Be sure there is still some fuel inside the fuel delivery unit.

Installing

• Tightening specification, refer to => [ Fuel Delivery Unit and Fuel Level Sensor (G) Overview ] Fuel Delivery Unit and Fuel Level Sensor (G) Overview.

Install in reverse order, paying attention to the following:

• Replace seal.

• When inserting fuel delivery unit, be sure not to bend floater arm on the fuel level sensor (G).

- Install the fuel delivery unit into the fuel tank.

- Install the new locking flange seal dry.






Risk of leaking.

• When inserting sealing flange, sealing ring must not be damaged or crushed.

- Press locking flange down against spring pressure and bring it into installation position.

• The tab - 2 - on locking flange must lie between tabs - 1 and 3 - on fuel tank.

• - Arrow - points in direction of travel.

- Tighten locking ring.






TT Coupe:

- Install rear seat bench.

- Connect the battery. Observe safety precautions after connecting battery.

TT Roadster:

- Installing fuel tank. Refer to => [ Installing ] Fuel Tank with Attachments.

All Vehicles:

- After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.

- On vehicles with TFSI engine, with toothed belt drive, a fuel pump adaptation must be performed after replacing the fuel delivery unit. Refer to => [ Toothed Belt Drive, Performing a Fuel Pump Adaptation after Replacing Fuel Delivery Unit ] Toothed Belt Drive, Performing a Fuel Pump Adaptation after Replacing Fuel Delivery Unit.