Fuel Delivery Unit: Installing

• Assembly overview, refer to Fuel Delivery Unit and Fuel Level Sensor Assembly Overview .
• Tightening specifications, refer to Fastener Tightening Specifications .

Installation is performed in the reverse order of removal, noting the following:

• Always replace seal and union nut.
• When inserting fuel delivery unit, be sure not to bend floater arm of fuel level sensor -G-.
• Ensure fuel hoses are seated securely.

• Insert fuel delivery unit into fuel tank with locking flange set aside.
• Attach the fuel delivery line -1-.
• Push the suction jet pipe -4- onto the suction jet pump until it engages audibly.
• Connect electrical connector -3- for fuel level sensor 2.
• Slide the new gasket -2- over the sealing flange and insert it in the groove on the fuel tank.
Fig 1: Fuel Delivery Line, Gasket, Electrical Connector & Suction Jet Pipe
Courtesy of AUDI OF AMERICA, LLC
• Make sure the fuel lines and electrical wires are routed correctly:
  • Route the fuel supply line -1- between the guide tube -4- and the supports -2- for the fuel return line. Also, it must be routed around the outside of the guide tube -3-.
• Insert the guide tubes -3- and -4- of the locking flange into the guide holes -arrows- of the fuel delivery unit.
  NOTE: To improve clarity, the fuel delivery unit is shown without the fuel tank.
Fig 2: Fuel Supply Line, Supports & Guide Tube
Courtesy of AUDI OF AMERICA, LLC
• Slide the fuel supply line clockwise - away from the fuel level sensor movement area - under the sealing flange.
  Fig 3: Sliding Fuel Supply Line Clockwise Away From Fuel Level Sensor Movement Area Under Sealing Flange

  Courtesy of AUDI OF AMERICA, LLC
• Slide the union nut -1- over the left arm and press the sealing flange forcefully -2- into the installation position with the left hand -arrow-.

• The tab -4- on locking flange must lie between tabs -3- and -5- on threaded ring.

Fig 4: Sliding Union Nut Over Left Arm And Pressing Sealing Flange Forcefully Into Installation Position With Left Hand

Courtesy of AUDI OF AMERICA, LLC

• With the right hand, slide the union nut -1- off the left arm while continuing the press the sealing flange -2- down forcefully with the left hand -arrow-.
• Position the union nut -1- with the right hand so the double ridge -5- on the ribbing lies over the tab -3- on the sealing flange (approximately the 10 o'clock position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it -4-.
• Continue pressing the sealing flange down forcefully.
• Rotate the sealing ring approximately 390° with the right hand until the double ridge -1- is in the 12 o'clock position while continuing to press the sealing flange down forcefully with the left hand.
Fig 5: Rotating Sealing Ring Approximately 390° With Right Hand Until Double Ridge Is In 12 O'clock Position While Continuing To Pressing Sealing Flange Down Forcefully With Left Hand
Courtesy of AUDI OF AMERICA, LLC

• Tighten the right sealing flange union nut with the -T40068 A-.

Fig 6: Tightening Right Sealing Flange Union Nut With -T40068 A-

Courtesy of AUDI OF AMERICA, LLC

• Verification: The double ridge -1- must now be between the 5 o'clock and 6 o'clock positions.
Fig 7: Double Ridge
Courtesy of AUDI OF AMERICA, LLC

• Install fuel supply line -1- and the fuel return line -2- according to the marking.
  Fig 8: Identifying Fuel Supply Line & Fuel Return Line

  Courtesy of AUDI OF AMERICA, LLC
• Connect electrical harness connector.
• Install rear seat bench. Refer to BENCH SEAT .
• Connect battery. Observe safety precautions after connecting battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
• Fill vehicle with at least 5 liters of fuel after installing fuel level sensor.