Overview - Fuel Delivery Unit/Fuel Level Sensor, TDI AWD Vehicles

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

Courtesy of AUDI OF AMERICA, LLC

1. Fuel Delivery Unit -GX1-
   • With the Transfer Fuel Pump -G6-
   • Check the fuel pump electronically using the Vehicle Diagnostic Tester.
   • Removing and Installing. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING, TDI VEHICLES .
   • Connector Couplings, Disconnecting and Connecting. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
   • It must be ensured that at least five liters of fuel are in the fuel tank after installation.
2. Clamp
   • Always replace after removing
3. Grommet
4. Clamp
   • Always replace after removing
5. Fuel Line
   • To the Metering Pump -V54-
   • For versions with parking/auxiliary heater
6. Fuel Supply Line
   • To the fuel filter
   • Clipped to the fuel tank
   • Do not kink
   • Connector Couplings, Disconnecting and Connecting. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
7. Fuel Pump Control Module -J538-
   • Check using the Vehicle Diagnostic Tester.
   • Removing and Installing. Refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING, VEHICLES WITHOUT HIGH-VOLTAGE SYSTEM .
8. Wire
   • For Fuel Delivery Unit -GX1- with fuel delivery unit for:
     • Transfer Fuel Pump -G6-
     • Fuel Level Sensor -G-
     • Fuel Pump Control Module -J538-
     • Equipment version: Metering Pump -V54-
   • Make sure it is attached securely
9. Fuel Return Line
   • From the engine
   • Clipped to the fuel tank
   • Do not kink
   • Connector Couplings, Disconnecting and Connecting. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
10. Locking Ring
    • 110 Nm
    • Loosen and tighten using the Wrench - Fuel Sending Unit: T10202 
11. Seal
    • Always replace
    • Install dry
12. Wire
    • With connectors for:
      • Fuel Level Sensor 2 -G169-
      • All-Wheel Drive Control Module -J492- with All-Wheel Drive Clutch Pump -V181-
      • Equipment version: Fuel Pump Control Module -J538-
    • Make sure it is attached securely
13. Locking Ring
    • 110 Nm
    • Loosen and tighten using the Wrench - Fuel Sending Unit: T10202 
14. Seal
    • Always replace
    • Install dry
15. Fuel Level Sensor 2 -G169-
    • Removing and Installing. Refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING .
16. Fuel Level Sensor -G-
    • Removing and Installing. Refer to Fuel Level Sensor -G-, REMOVING AND INSTALLING .