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

-- Observe the safety instructions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking when removing the fuel delivery unit, the fuel tank may only be a maximum of ¹ /₄ full.

-- If required, drain the fuel tank. Refer to FUEL TANK, DRAINING .

-- Move the front seats all the way forward into the highest position.

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

-- Remove the bolts -arrows- and remove the sealing flange cover -1-.

Fig 1: Sealing Flange Cover

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connectors -1 and 3- on the sealing flange by unlocking the connector safety catch.

Fig 2: Fuel Pump Connectors

Courtesy of AUDI OF AMERICA, LLC

-- Country/Rest of World equipment versions: release the connector safety catch and disconnect the connector -2-.

-- Country/Rest of World equipment version: disconnect the fuel line -1- to the metering pump. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Courtesy of AUDI OF AMERICA, LLC

WARNING:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Disconnect fuel lines -2 and 3-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 3: Identifying Fuel Sending Unit Wrench

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Danger due to escaping fuel.

To prevent large quantities of fuel from leaking when removing the fuel delivery unit, the fuel tank may only be a maximum of ¹ /₄ full.

-- Remove the locking ring using the :T10202 .

-- Pull the sealing flange -1- slightly out of the fuel tank opening and remove the seal -2-.

Courtesy of AUDI OF AMERICA, LLC

-- Carefully pull the sealing flange with the fuel lines out of the fuel tank opening.

-- Release the connector safety catch and disconnect the connectors from the sealing flange.

Courtesy of AUDI OF AMERICA, LLC

For Fuel Level Sensor -G-
For Fuel Level Sensor 2 -G169-, present depending on the vehicle version

FWD Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Reach through the opening in the fuel tank and disconnect the suction jet line -arrow-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

AWD Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Reach through the opening in the fuel tank and disconnect the suction jet line -arrow-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Continuation for All Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Reach through the opening in the fuel tank, push the catches -1 and 3- one after the other in the direction of the -arrow- and at the same time release the fuel delivery unit -2-.

WARNING:

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 from the fuel tank opening.

NOTE:

For reasons of clarity, the fuel delivery unit is shown without the fuel lines.