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

WARNING: This page is about a different car, the 2016 Audi A6 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Install in reverse order of removal. Note the following:

NOTE:

Replace the seal.

Make sure the fuel hoses are secure.

When inserting fuel delivery unit, be sure not to bend floater arm on the Fuel Level Sensor -G-.

-- Route the Ground (GND) cable as illustrated.

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GND Cable to Locking Flange
Locking Flange
Fuel Pressure Regulator
GND Cable to Fuel Pressure Regulator

Make sure the fuel hoses are routed correctly:

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-- Connect the fuel supply hose -1- to the fuel delivery unit -7-.

-- Insert the fuel return hose -4- into the guide on the fuel delivery unit -7-.

-- Insert the guide tubes -2 and 6- with the locking flange pressure spring -3- into the guides on the fuel delivery unit.

-- If the vehicle has a parking heater, make sure the intake line -5- to the metering pump is connected securely in the guide on the fuel delivery unit.

-- Guide the Fuel Level Sensor 2 -G169- wire out of the fuel tank.

-- Carefully install the fuel delivery unit and Fuel Level Sensor -G- back into the fuel tank.

-- Make sure the Fuel Level Sensor 2 -G169- wire is installed correctly:

Guide the Fuel Level Sensor 2 -G169- wire -4- next to the guide tubes -2 and 3- and above the fuel supply hose -1-.

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Guide the wire -4- past the wires -5- for the Fuel Level Sensor -G- and -6- for the Transfer Fuel Pump -G6-.

-- Connect the connector -2- for the Fuel Level Sensor 2 -G169- to the locking flange -1- and make sure it is locked secure.

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Verification:

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The locking flange guide pipes -2 and 3- must be inserted into the guides on the fuel delivery unit.
Vehicles with parking heater: the intake line -1- to the parking heater metering pump must be inserted into the guide on the fuel delivery unit.

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

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CAUTION:

Risk of leaking.

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

-- Bring the locking flange into the installation position.

The tab -1- on the locking flange must face the hole -arrow- in the retaining ring and between the tabs -2 and 3- on the fuel tank.

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

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

-- Install the right locking flange cover. Refer to .

-- Install the rear bench seat. .

-- After installing fuel delivery unit, fill vehicle with at least 5 liters (5.28 qts) of fuel.

-- Vehicles with parking heater: To vent the fuel line to the auxiliary heater metering pump, run for 10 minutes at wide open throttle.