Fuel Delivery Unit and Fuel Level Sensor Assembly Overview

Fig 1: Fuel Delivery Unit And Fuel Level Sensor, Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

1. Fuel Delivery Unit
   • Fuel pump electrical, checking, refer to Fuel Pump Electrical, Checking .
   • Removing and installing, refer to Fuel Delivery Unit .
   • After installing, fuel vehicle with at least 5 liters of fuel.
   • Checking residual pressure, refer to the appropriate Fuel Injection and Ignition information.
2. Fuel Level Sensor -G-
   • Resistance values, checking, refer to Fuel Level Sensor, Checking .
   • Removing and installing, refer to Fuel Level Sensor .
3. Threaded Ring
4. Seal
   • Replace.
   • Install dry.
5. Union Nut, 120 Nm
   • Use ring nut wrench - T40068 A- for removal and installation.
   • Replace.
6. Fuel Return Line
   • From fuel filter.
   • Do not kink.
   • Mark before removing.
   • To remove from locking flange, press release button on connecting piece.
   • Note direction of arrow (fuel supply or return) on locking flange when installing.
   • Clipped in on fuel tank.
7. Fuel Supply Line
   • To fuel filter.
   • Do not kink.
   • Mark before removing.
   • To remove from locking flange, press release button on connecting piece.
   • Note direction of arrow (fuel supply or return) on locking flange when installing.
   • Clipped in on fuel tank.
8. Electrical Harness Connector
   • For Transfer Fuel Pump (FP) -G6-.
   • For fuel level sensor and Fuel Level Sensor 2 -G169-.
9. Electrical Harness Connector
   • For fuel level sensor 2.
10. Fuel Delivery Line
    • From suction jet pump to fuel delivery unit.
    • Clipped into fuel delivery unit.
    • Secure to suction jet pipe with a total of 3 cable ties.
    • Follow the installation instructions, refer to Suction Jet Pump 
11. Union Nut, 120 Nm
    • Use ring nut wrench -T40068 A- for removal and installation.
    • Replace.
12. Seal
    • Replace.
    • Install dry.
13. Threaded Ring
14. Suction Jet Pump
    • Checking, refer to Suction Jet Pump .
    • Removing and installing, refer to Suction Jet Pump .
    • After installing, fuel vehicle with at least 5 liters of fuel.
15. Fuel Level Sensor 2 -G169-
    • Resistance values, checking, refer to Fuel Level Sensor 2, Checking .
    • Removing and installing, refer to Fuel Level Sensor 2 .
16. Suction Jet Pipe
    • From fuel pump to suction jet pump.
    • To disconnect, press release button on connection piece.
    • Secure on fuel delivery line with a total of 3 cable ties.
    • Follow the installation instructions. Refer to Suction Jet Pump .