Overview - Fuel Delivery Unit/Fuel Level Sensor, TFSI Vehicles

Fig 1: Exploded View Of Fuel Delivery Unit/Fuel Level Sensor, TFSI Vehicles

Courtesy of AUDI OF AMERICA, LLC

1. Fuel Delivery Unit
   • With the Transfer Fuel Pump -G6-
   • With integrated fuel filter; the fuel filter cannot be replaced separately
   • It must be ensured that at least five liters of fuel are in the fuel tank after installation.
   • Perform an electrical test on the fuel pump. Refer to Vehicle Diagnostic Tester.
   • Removing and Installing. Refer to FUEL DELIVERY UNIT, REMOVING AND INSTALLING, TFSI VEHICLES .
   • Connector Couplings, Disconnecting and Connecting. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
2. Fuel Line
   • To the engine
   • Do not kink
   • Clipped to the fuel tank
   • Connector Couplings, Disconnecting and Connecting. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
3. Nut
   • 3 Nm
   • Quantity: 2
4. Fuel Pump Control Module -J538-
   • Component location: lower right on the underbody
   • Checking. Refer to Vehicle Diagnostic Tester.
   • Removing and Installing. Refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING .
5. Wiring Harness
   • Make sure it is attached securely
6. Fuel Line
   • To the metering pump for versions with parking/auxiliary heater
   • Clipped to the fuel tank
   • Do not kink
   • Connector Couplings, Disconnecting and Connecting. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
7. Locking Ring
   • 110 Nm
   • Loosen and tighten using the Wrench - Fuel Sending Unit: T10202 
8. Seal
   • Replace after removing.
   • Install dry
9. Connector
   • For the Fuel Level Sensor 2 - G169-, Fuel Level Sensor 4 - G393-
   • Make sure it is attached securely
     CAUTION:

     The Fuel Level Sensor 2 - G169- and Fuel Level Sensor 4 - G393- are integrated in the fuel tank and cannot be replaced separately.

     Checking. Refer to Vehicle Diagnostic Tester.

10. Fuel Level Sensor -G-
    • Checking. Refer to the appropriate Service Information.
    • Removing and Installing. Refer to Fuel Level Sensor -G-, REMOVING AND INSTALLING .

Sealing Flange Cover - Tightening Specification 

Fig 2: Sealing Flange Cover

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts -arrows- on the cover -1- to 1.5 Nm.