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

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-- Guide the fuel line -2- out of the fuel tank and mount it on the fuel delivery unit until it clicks into place.

-- Carefully guide the fuel delivery unit -1- with screen and wires into the fuel tank.

-- Reach in the fuel tank and carefully turn the fuel delivery unit -1- with screen into the installation position in direction of -arrows-.

Fig 1: Installing Fuel Delivery Unit

Courtesy of AUDI OF AMERICA, LLC

-- Reach in the fuel tank and mount the fuel line -2- on the fuel delivery unit until it clicks into place.

-- Push the fuel delivery unit -3- in direction of -arrow- into the baffle housing retainers.

-- Connect the connector -1- and make sure it is securely locked.

Fig 2: Connecting Fuel Line, Seating Fuel Delivery Unit And Connecting Connector

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

NOTE:

Replace the seal.

Make sure the fuel hoses are secure.

-- Connect the connectors -3 and 5- and make sure they are securely locked.

Fig 3: Identifying Sealing Flange, Fuel Lines, Connectors And Seals

Courtesy of AUDI OF AMERICA, LLC

-- Insert the fuel line -2- until it audibly latches to the sealing flange.

-- Install a new dry sealing flange seal -4-.

-- Insert the sealing flange -1- into the fuel tank.

CAUTION:

Risk of leaking.

When inserting sealing flange, sealing ring must not be damaged or crushed.

-- Set the sealing flange into the installation position.

The tab -2- on the right sealing flange must lie between latches -1 and 3- on the fuel tank.
The >>arrow<< on the sealing flange must point in direction of travel.

Fig 4: Identifying Tab And Latches

Courtesy of AUDI OF AMERICA, LLC

-- Attach the fuel lines so that they audibly latch.

-- Connect the connectors and make sure they are secure.

-- Install the sealing flange cover, refer to Figure.

-- Install the rear bench seat or single seat, refer to Rear Seats .

-- Follow all steps after connecting the battery, refer to BATTERY .

-- After installing fuel delivery unit, fill vehicle with at least 5.5 liters (5.8 qts) of fuel.

-- Vehicles with auxiliary heater: To vent the fuel line to the auxiliary heater metering pump, run for 10 minutes at Wide Open Throttle (WOT).