TSB : Fuel Delivery Unit, Removing And Installing, A5 Through My 2011, A4 Through My 2012, Rest Of World Vehicles With Fwd: Removing

Details

-- Follow all safety precautions. 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 from the fuel delivery unit when removing, the fuel tank may only be a maximum of 1 / 4 full. -- If required, empty the fuel tank. Refer to FUEL TANK, DRAINING, REST OF WORLD VEHICLES WITH FWD . -- Move the passenger seat all the way forward if necessary. CAUTION: Risk of destroying electronic components when disconnecting the battery. Observe the steps for disconnecting the battery. -- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING . -- Remove the rear bench seat. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING . Fig 1: Identifying Cover Bolts For Locking Flange Courtesy of AUDI OF AMERICA, LLC -- Remove the locking flange cover -arrows-. -- If equipped, disengage the connector -2- to the parking heater metering pump at the locking flange and move it to the side. Fig 2: Identifying Locking Flange Components Courtesy of AUDI OF AMERICA, LLC -- Disconnect the connector -1- on the sealing flange. -- Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-. Fig 3: Pulling Lock -1- Upward -Arrow A- & Press -Arrow B- Courtesy of AUDI OF AMERICA, LLC Fig 4: Connect Fuel Lines -1 And 2- Courtesy of AUDI OF AMERICA, LLC WARNING: 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. -- Remove the fuel line -2- from the locking flange. Refer to CONNECTOR COUPLINGS, SEPARATING . -- Disconnect the fuel line -1- to the auxiliary heater metering pump at the locking flange, if necessary. Refer to CONNECTOR COUPLINGS, SEPARATING . Fig 5: Disconnecting Fuel Line To Auxiliary Heater Metering Pump At Locking Flange By Pressing Release Button Courtesy of AUDI OF AMERICA, LLC WARNING: Danger due to escaping fuel. To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of 1 / 4 full. -- Use a Fuel Tank Sender Unit Tool :T40068A to remove the union nut -arrow-. NOTE: When union nut is loosened, plastic catch on threaded ring breaks off - ignore. -- Remove the locking flange -2- with fuel filter from the fuel tank and tip it slightly to the left side of the vehicle. Fig 6: Identifying Locking Flange -2- With Fuel Filter Removed From Fuel Tank And Tipped Slightly To Left Side Of Vehicle Courtesy of AUDI OF AMERICA, LLC -- Remove the seal -1-. -- Pull the locking flange with fuel filter away from the fuel delivery unit slightly -arrow A-. -- At the same time, tilt the locking flange with fuel filter out of the fuel tank -B arrows-, being especially careful of the retaining plate with the ground connection -3- and the fuel line -4-. Fig 7: At Same Time, Tilt Locking Flange With Fuel Filter Out Of Fuel Tank Courtesy of AUDI OF AMERICA, LLC WARNING: There is a risk of fuel leaking out from the filled fuel delivery unit. Lay cloths below to catch the leaking fuel. -- Pull the locking flange -2- with fuel filter away from the fuel delivery unit -1- slightly again -arrow A-. -- Tilt the fuel delivery unit to the left side of the vehicle -arrow B- and pull it out of the fuel tank slightly. NOTE: Be careful not to bend the floater arm on the Fuel Level Sensor -G- when removing the fuel delivery unit. -- Guide the Fuel Level Sensor -G- -item 3- out of the fuel tank opening and remove the fuel delivery unit with suction line from the fuel tank.