Fuel Pump (FP) and Sender For Fuel Gauge - Component Overview

Fuel Pump (FP) And Sender For Fuel Gauge - Component Overview

Part I
1. Sender for fuel gauge -G-
- Clipped in at baffle housing in fuel tank
2. Fuel pump
- Different versions, allocation.
- Can be replaced only complete with connector flange
- Check Fuel Pump (FP) electrically
- Checking fuel delivery
- Checking residual pressure
3. Electrical harness connector
- For Fuel Pump (FP) and sender for fuel gauge -G-
- Disengaging, see Fig. 1
4. Connector flange
- For Fuel Pump (FP)
- Not individually replaceable
- Installation position
5. Ventilation line
- From fuel pressure regulator in fuel filter
- To disconnect, press release button on connection piece
- Do not bend
- Clipped in on fuel tank
6. Seal
- Always replace
- To install, place into opening of fuel tank dry
7. Locking ring
- Use ring nut wrench 3087 to remove and install
- Tighten to 145 Nm
8. Fuel supply line
- To fuel filter
- To disconnect, press release button on connection piece
- Do not bend
- Clipped in on fuel tank
9. Union piece
- Different versions, allocation.
- Clipped in on baffle housing with catches
- To remove, press toward right so that catches disengage and lift upward
10. Fuel line
- To suction jet pump in baffle housing
11. Fuel return line
- From connector flange, left side
12. Fuel delivery line
- From suction jet pump, right side
13. Baffle housing
- With suction jet pump

Part II
1. Baffle housing
- With suction jet pump
2. Union piece
- Different versions, allocation.
- Clipped in on baffle housing with catches
- To remove, press toward right so that catches disengage and lift upward
3. Fuel line
- To suction jet pump in baffle housing
4. Fuel return line
- From connector flange, left side
5. Fuel return line
- From fuel filter
- To disconnect, press release button on connection piece
- Do not bend
- Clipped in on fuel tank
6. Seal
- Always replace
- To install, place into opening of fuel tank dry
7. Locking ring
- Use ring nut wrench 3087 to remove and install
- Tighten to 145 Nm
8. Electrical harness connector
- For Fuel Level Sensor 2 -G169-
- Disengaging, see Fig. 1
9. Connector flange
- Only available together with -item 10-
- Installation position
10. Fuel Level Sensor 2 -G169-
- Only available together with -item 9-
11. Suction jet pump
- With lines
- Different versions, allocation
- Secured on connector flange
12. Fuel delivery line
- From suction jet pump, right side

Fig. 1 Releasing harness connector

- To disconnect the multi-pin harness connector at Fuel Pump (FP), the harness connector must be released. This can be done by hand or by using a small screwdriver (arrow).

Removing and installing fuel pump

CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 1/4. Empty fuel tank if necessary.

Recommended special tools and equipment

- 3087 wrench for tank sensor

- Fuel Pump Wrench 3307

- VAS5190 fuel siphoning device

Empty fuel tank
Observe safety precautions.
Observe rules for cleanliness.

CAUTION:
- On vehicles equipped with Audi Telematics by OnStar (R), switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery. Use must use the VAS 5051 or VAS 5052.
- The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged.

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

CAUTION: Secure Ground (GND) wire of VAS5190 to a blank portion of the chassis.

- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark (arrow) on hose at length a = 1,865 mm from end of suction hose.
- Remove fuel filler cap from fuel filler tube.

- Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
- Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

NOTE: If using a siphoning device without shaft piece, proceed principally in the same manner.

- In this case, apply a mark (arrow) on hose at length a = 1,800 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
- If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

- Drain fuel tank through fuel filler tube as much as possible.
- Carefully remove siphoning hose.
- Remove rear seat bench.

- Remove cover for right connector flange (arrows).

- Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
- Disengage electrical harness connector -2- and lay it aside.

CAUTION: Fuel system is under pressure. Before opening system, place rags around the connection area. Then release pressure by carefully loosening connection.

- Disconnect fuel supply line -1- from connector flange (right side of vehicle).
- Disconnect ventilation line -2- (press release button).

- Use 3087 wrench to remove locking ring.
- Pull connector flange and sealing ring from opening of fuel tank.

- Disconnect harness connector (arrow) to fuel gauge on the inside of connector flange.

- Slide suction hose for a length of dimension x = 800 mm through right opening on fuel tank to left tank chamber.
- Empty left fuel tank chamber.
- Remove rear seat bench.

- Remove cover for right connector flange (arrows).

- Disconnect fuel supply line -1- and ventilation line -2- from connector flange (right side of vehicle) (press release button).

- Use e.g. 3087 wrench to remove locking ring.
- Pull connector flange and sealing ring from opening of fuel tank.

- Disconnect harness connector (arrow) to fuel gauge on the inside of connector flange.

- Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
- Rotate Fuel Pump (FP) toward left approx. 15 degrees to stop.

- Notch -1- aligns with marking -2- (bayonet connection)

- Remove Fuel Pump (FP).

Installing
Installation is the reverse of removal, noting the following:
- Insert new, dry seal for connector flange of fuel level sensor 2 into opening of fuel tank.

- Note the installation position of connector flange of fuel level sensor 2:
- The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

NOTE: Arrow points in direction of travel.

- Tighten locking ring.

- Insert Fuel Pump (FP) into baffle housing in tank so that the notch -1- at the Fuel Pump (FP) aligns with the marking -2- at the baffle housing.
- Fuel Pump (FP) can be pressed downward significantly and noticeably

- Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
- Rotate Fuel Pump (FP) toward right approx. 15 degrees to stop.

- Notch -1- aligns with marking -3- (bayonet connection)

- Connect harness connector (arrow) for fuel gauge on inside of connector flange.
- Insert new, dry seal for connector flange into opening of fuel tank.

- Note installation position of connector flange:
- The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

NOTE: Arrow points in direction of travel.

- Tighten locking ring.
- Observe safety precautions after connecting the battery.

Tightening torques

Component Nm
Locking ring for Fuel Pump (FP) or 145
connector flange of fuel level sensor 2
Battery terminal to battery post 6

Final procedures
After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence:
1. Vent fuel system.
2. Check DTC memory. Mode 3: Check DTC Memory
3. If necessary, erase DTC memory. Mode 4: Reset/Erase Diagnostic Data
4. Generate readiness code. Readiness Code, Generating

- End diagnosis and switch ignition off.