Note: Before starting work, read the warnings contained in paragraph 7. A special Audi/VAG tool is required to remove the inner section of the damping housing.
Withdrawal
1. The pump and sensor are combined into one unit installed in the fuel tank. Access to it is possible through the hatch in the floor of the luggage compartment. Removal involves exposing the contents of the tank to the atmosphere - take special fire precautions. The surrounding area around the vehicle must be well ventilated so that fuel vapors do not accumulate. If possible, remove the block when the tank is as empty as possible or pump the fuel into a suitable canister.
2. Depressurize the fuel system as described in paragraph 9.
3. Install the car horizontally. Disconnect the wire "masses" battery as described in chapter 5A.
4. As described in chapter 11, remove the trim from the luggage compartment floor.
5. Loosen the screws securing the hatch and remove it from the floor (pic. 7.5).
6. Disconnect the electrical connector from the pump/sensor assembly (pic. 7.6).
7. Lay a rag under the fuel collection hoses. Loosen the clamps and remove the supply and return hoses (pic. 7.7). Place tags on the hoses to avoid confusion during installation. Release the tubes from the fasteners on the support ring.
8. Remember the direction of the arrows and the ring, unscrew the plastic ring for attaching the block to the back. Audi/VAG mechanics have a special tool for this operation. However, for this it is enough to insert two screwdrivers into the slots of the ring and cross them. You can use a large wrench "dog" (pic. 7.8, a, b).
9. Remove the flange and seal from the tank opening.
10. Disconnect the sensor wiring and free it from the flange (pic. 7.10).
11. Pull off the shell, disconnect the fuel return pipe from the bottom of the flange (pic. 7.11).
12. Rotate the inner section of the damping housing counterclockwise by approximately 15°and remove it together with the fuel pump (pic. 7.12). Audi mechanics use a special tool for this, aligning it with the cutouts at the top of the pump - it is highly recommended to use it. You can make homemade, however, the plastic is very fragile - you can break it. If the pump is to be replaced, drain all fuel from the old block. The flange can be removed from the pump by loosening the clamp and disconnecting the intermediate supply tube. Remember how to install it in order to assemble everything correctly.
13. To remove the sensor, inside the tank press the latch on the side of the damping housing. Carefully remove the sensor (pic. 7.13, a, b).
14. Inspect the sensor float - there should be no holes in it and no fuel should gurgle in it. Replace damaged float. A damaged seal in the tank opening must also be replaced. Inspect the slider and sensor rheostat - there should be no breaks in the conductor. Remove any possible dirt from the rheostat
Installation
15. Insert the sensor into the damping housing, press until the lock snaps into place.
16. If the flange was removed from the pump, attach the intermediate supply tube and tighten the clamp (pic. 7.16).
17. Insert the inner damping housing with the pump into the outer housing as follows. so that the protrusion on the top edge aligns with the first notch on the body. Push the pump housing down with an open end wrench and turn it clockwise until it lines up with the second mark on the housing.
18. Attach the fuel return pipe to the bottom of the flange.
19. Attach the fuel gauge wiring to the inside of the flange and connect it to the bottom of the flange. The wiring must be wrapped once around the fuel return pipe.
20. Lubricate the new rubber seal with clean fuel, install on the flange, install the flange in the fuel tank opening.
21. Install the support ring, then wrap and tighten the plastic one. To ensure that the arrows line up when tightening the ring, turn the flange slightly counterclockwise while tightening the ring.
22. Attach fuel hoses and tighten collars.
23. Connect the wiring connector to the pump/sensor assembly.
24. Install the hatch and tighten the screws to secure it.
25. Establish an overlay on a floor of a luggage space.
26. Connect the battery as described in chapter 5A.
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