Fuel Supply System - Engine Code(s): Caeb, Cala & Caua (coupe) (as of 05.2012) Audi A5 I

FUEL TANK, DRAINING

Special tools and workshop equipment required

1. Fuel Siphoning Device VAS 5190

Procedure

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Disconnect the battery. Refer to Removal and Installation .

Scheme 73

Remove the cone piece -2- from the shaft piece -1- on the VAS 5190.

Attach insulating tape -arrow- to the hose at a distance -a- = 1, 300 mm (51.18 in.) from the end of the suction hose.

Remove the cover from the fuel filler tube.

Scheme 74

Install the adapter -1- for the VAS 5190 on the fuel filler tube.

Slide the suction hose into the fuel tank far enough so the mark applied earlier -arrow- is aligned with the shaft piece.

Empty the fuel tank through the fuel filler tube.

Remove the extracting hose carefully.

Note. Proceed the same way if the fuel siphoning device available does not have a shaft piece. In this case, apply a mark -arrow- using insulating tape on hose at length -a- = 1, 235 mm (48.62 in.) from the end of suction hose -1-. The suction hose is inserted correctly when the marking applied earlier aligns with the lip of the fuel filler neck. Coat the hose with a thin layer of engine oil if it is difficult to insert. Never use lubricants containing silicon.

FUEL SYSTEM, BLEEDING

1. Due to the engine design and the fuel supply pump installed in the fuel tank, do not bleed the fuel system.
2. The fuel system bleeds itself when the starter is operated.

FUEL SUPPLY LINE TO METERING PUMP, VEHICLES WITH AUXILIARY HEATER, BLEEDING

Note. After working on the fuel delivery unit, bleed the fuel supply line for the metering pump on vehicles with an auxiliary heater.

Special tools and workshop equipment required

1. Suction Pump VAS 5226
2. Hand Vacuum Pump VAS 6213

Procedure

Scheme 75

1. Parking heater switched off.

Connect the VAS 5226 to compressed air.

Remove the fuel supply line -2- from the fuel tank at the metering pump -1-.

Connect the VAS 5226 with the adapter from the VAS 6213 to the fuel supply line and bleed it by extracting briefly.

Install the fuel supply line to the metering pump.

Switch the parking heater on and let it run approximately 10 minutes under full load.

LEAK DETECTION SYSTEM

Function

The leak detection system recognizes leaks in the complete fuel system, including the fuel tank, Evaporative Emission (EVAP) canister and EVAP canister purge regulator valve 1 -N80-.

On the mechanical side, the leak detection system consists mainly of a vacuum-driven diaphragm pump, that is equipped with a reed contact on the actuation rod of the pump diaphragm. The pump is supplied with vacuum via the mechanical vacuum pump or the engine intake stroke.

1. When leak detection is activated, the diaphragm pump pumps the fuel system up to 20 to 30 mbar. The pump diaphragm is then moved out so that the reed contact at the operating rod remains in the "open" position.
2. During leak diagnosis, the reed contact is monitored to check if it remains open within 15 seconds. This indicates the system is sealed.
3. If the pressure falls (indicating a leak), the diaphragm moves back and the reed contact closes.
4. If reed contact closes within 15 seconds of leak detection time, a further test is performed: In this case the diaphragm pump pumps 4 times again. The Engine Control Module (ECM) measures the time for each of the 4 pumps until the reed contact is closed again. From that, the ECM can recognize a "small leak" (smaller than 1 mm in diameter) or a "large leak".

The leak detection is activated automatically, shortly after each cold engine start (under 35 °C (95 °F)) and a continual drive faster than 10 km/h (6.2 miles/per hour). In case a fault is detected, a Diagnostic Trouble Code (DTC) will be stored to memory. The Malfunction Indicator Lamp (MIL) in the instrument cluster lights up if the malfunction is recognized for 2 subsequent starts. Leak diagnosis can also be activated using the vehicle diagnostic tester. Refer to LEAK DETECTION TEST, PERFORMING .

Note. After the cold start, the leak detection can be repeated up to 10 times within the first 20 minutes. It can be determined if an automatic leak diagnosis was recently performed in measuring value block 071. Refer to LEAK DETECTION TEST, PERFORMING .

Scheme 76

1. Accelerator Pedal Module With accelerator pedal position sensor -G79- and accelerator pedal position sensor 2 -G185- Removing and Installing, refer to «Accelerator Pedal Position Sensor -G79- WITH Accelerator Pedal Position Sensor 2 -G185»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__accelerator-pedal-position-sensor-g79-with) Perform after the first kick-down adaptation in Guided Functions vehicle diagnostic tester.
2. Pedal Bracket
3. Bolt 8 Nm
4. Connector

Scheme 77

1. Bolt Tightening specification, refer to «[For engine(s) CAUA] Description and Operation»(ref-520111-S11301332932012123100000)
2. Exhaust System Suspended Mount
3. Mounting Strap
4. Fuel Line From the fuel filter to the engine Do not kink Clipped to the fuel tank To disconnect, press release button on connection piece
5. Bolt 8 Nm
6. Protective Plate For the fuel filler tube
7. Overflow Hose Attached to the bumper bracket
8. Rubber Gasket
9. Cap Turn until it clicks and locks. Attached to tank flap unit with fastening device
10. Bolt 20 Nm To attach the fuel filler neck For discharging electrostatic charge (Scheme 80)
11. Fuel Tank Removing and Installing, refer to «FUEL TANK WITH ATTACHMENTS»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-tank-with-attachments)
12. Vent Line To the Evaporative Emission (EVAP) canister Do not kink To disconnect, press release button on connection piece Clipped to the fuel tank
13. Fuel Tank Heat Shield
14. Nut 2 Nm
15. Nut 2 Nm
16. Carrier Plate
17. Fuel Tank Heat Shield
18. Nut 2 Nm
19. Bolt 20 Nm
20. Nut 2 Nm
21. Expanding Clip

Scheme 78

Tighten bolts -arrows- to 1.5 Nm.

Scheme 79

Make sure the filler tube threaded connections -1 and 2- are free of corrosion so the Ground (GND) connection to the body is not affected.

Scheme 80

1. Fuel Delivery Unit Electric fuel pump, checking, refer to «ELECTRIC FUEL PUMP, CHECKING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) Check the fuel pressure, residual pressure and fuel delivery rate: 4-Cylinder «FUEL PRESSURE, RESIDUAL PRESSURE AND FUEL DELIVERY RATE, CHECKING, VEHICLES WITH 4-CYLINDER ENGINES»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) 6-Cylinder «FUEL PRESSURE, RESIDUAL PRESSURE AND FUEL DELIVERY RATE, CHECKING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) 8-Cylinder «FUEL PRESSURE, RESIDUAL PRESSURE AND FUEL DELIVERY RATE, CHECKING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) Removing and installing, refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) Fill the fuel tank with at least 5 liters (5.28 quarts) of fuel after installing
2. Threaded Ring
3. Seal Replace Install dry
4. Union Nut 120 Nm Replace Use fuel tank sender unit tool T40068 A for loosening and tightening
5. Fuel Line To the engine Do not kink To remove from locking flange, press release button Clipped to the fuel tank
6. Connector For the transfer fuel pump -G6- and fuel level sensor -G
7. Connector For the fuel pump control module -J538
8. Spring Nut
9. Fuel Pump (FP) Control Module -J538- Removing and installing, refer to «Fuel Pump Control Module -J538»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-pump-control-module-j538)
10. Bolt 2.5 Nm
11. Connector For fuel level sensor 2 -G169
12. Vent Line To the Evaporative Emission (EVAP) canister Do not kink To remove from locking flange, press release button Clipped to the fuel tank
13. Union Nut 120 Nm Replace Use fuel tank sender unit tool T40068 A for loosening and tightening
14. Seal Replace Install dry
15. Threaded Ring
16. Locking Flange With the fuel level sensor 2 -G169
17. Vent Line To remove from locking flange, press release button Clipped to the fuel tank
18. Vent Line To remove from locking flange, press release button Clipped to the fuel tank
19. Fuel Level Sensor 2 -G169- Check the resistance values. Refer to «Fuel Level Sensor 2 -G169-, CHECKING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-level-sensor-2-g169-checking) Removing and installing, refer to «Fuel Level Sensor 2 -G169»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-level-sensor-2-g169) Fill the fuel tank with at least 5 liters of fuel after installing
20. Suction Line Removing and installing, refer to «SUCTION LINE»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) Fill the fuel tank with at least 5 liters (5.2 quarts) of fuel after installing
21. Connector For fuel level sensor 2 -G169
22. Fuel Level Sensor -G- Check the resistance values. Refer to «Fuel Level Sensor -G-, CHECKING»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-level-sensor-g-checking) Removing and installing, refer to «Fuel Level Sensor -G»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012)

Scheme 81

1. Fuel Line To disconnect, press release button on connection piece
2. O-ring Replace
3. Locking Flange
4. Fuel Delivery Unit
5. Fuel Filter Removing and installing, refer to «FUEL FILTER»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012)
6. Ground (GND) Wire Connect to the retaining plate
7. Fuel Pressure Regulator Retaining Plate With a GND connection

Scheme 82

1. Leak Detection Pump -V144- Installed location: on the left side at the back of the underbody under the cover Check in Guided Fault Finding vehicle diagnostic tester Removing and installing, refer to «Leak Detection Pump -V144»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) Leak detection pump -V144- air filter, removing and installing, refer to «Leak Detection Pump -V144- AIR FILTER»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .
2. Clamp Must be appropriate for the model type.
3. Vent Line
4. Bolt 4 Nm
5. Bolt 16 Nm
6. Rubber Grommet
7. Bushing
8. Evaporative Emission (EVAP) Canister Installed location: In the bottom of the spare wheel well Removing and installing, refer to «EVAP CANISTER»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__evap-canister)
9. Vent Line To the locking flange on the fuel tank To disconnect, press release button on connection piece
10. Vent Line To EVAP canister purge regulator valve 1 -N80- To disconnect, press release button on connection piece
11. Seal
12. Vacuum Line To the engine

Scheme 83

Tighten the nut -2- to 5 Nm.

Scheme 84

1. Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80
2. Vent Line From the fuel tank locking flange to the EVAP canister Clipped into brackets under the vehicle underbody
3. Fuel Tank Locking Flange
4. Air Filter For the leak detection pump -V144
5. Connecting Line From the leak detection pump -V144- to the air filter Clipped into brackets under the vehicle underbody
6. EVAP Canister Installed location: Under the luggage compartment floor Removing and installing, refer to «EVAP CANISTER»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__evap-canister)
7. Leak Detection Pump -V144- Installed location: On the EVAP canister under the bottom of the luggage compartment Check in Guided Fault Finding vehicle diagnostic tester Removing and installing, refer to «Leak Detection Pump -V144»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012)
8. Vent Line From the EVAP canister to EVAP canister purge regulator valve 1 -N80- Clipped into brackets under the vehicle underbody
9. Vacuum Line From the engine to the leak detection pump -V144- Clipped into brackets under the vehicle underbody

EVAP CANISTER AND LEAK DETECTION SYSTEM HOSE DIAGRAM [FOR ENGINE(S) CALA, CCBA, CGXC]

Note. Pictured here is the hose diagram for the 3.2 L FSI engine

Scheme 85

1. Vent Line From the EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- Clipped into brackets under the vehicle underbody
2. Vacuum Line From the engine to the leak detection pump -V144- Clipped into brackets under the vehicle underbody
3. Vent Line From the fuel tank locking flange to the EVAP canister Clipped into brackets under the vehicle underbody
4. Fuel Tank Locking Flange
5. Air Filter For the leak detection pump -V144
6. Connecting Line From the leak detection pump -V144- to the air filter Clipped into brackets under the vehicle underbody
7. EVAP Canister Installed location: Under the luggage compartment floor Removing and installing, refer to «EVAP CANISTER»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__evap-canister)
8. Leak Detection Pump -V144- Installed location: On the EVAP canister under the bottom of the luggage compartment Check in Guided Fault Finding vehicle diagnostic tester Removing and installing, refer to «Leak Detection Pump -V144»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012)
9. To Brake Booster
10. EVAP Canister Purge Regulator Valve 1 -N80

Scheme 86

1. Vacuum Line From the engine to the leak detection pump -V144- Clipped into brackets under the vehicle underbody
2. Vent Line From the fuel tank locking flange to the Evaporative Emission (EVAP) canister Clipped into brackets under the bottom of the luggage compartment
3. Fuel Tank Locking Flange
4. Air Filter For the leak detection pump -V144
5. Connecting Line From the leak detection pump -V144- to the EVAP canister Clipped into brackets under the vehicle underbody
6. EVAP Canister Installed location: Under the luggage compartment floor Removing and installing, refer to «EVAP CANISTER»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__evap-canister)
7. Leak Detection Pump -V144- Installed location: On the EVAP canister under the bottom of the luggage compartment Check in Guided Fault Finding vehicle diagnostic tester Removing and installing, refer to «Leak Detection Pump -V144»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012)
8. Vent Line From the EVAP canister to EVAP canister purge regulator valve 1 -N80- Clipped into brackets under the vehicle underbody
9. EVAP Canister Purge Regulator Valve 1 -N80

FASTENER TIGHTENING SPECIFICATIONS

ELECTRIC FUEL PUMP, CHECKING, A5 THROUGH MY 2011, A4 THROUGH MY 2012

Special tools and workshop equipment required

1. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
2. Multimeter V.A.G 1526D
3. Connector Test Set V.A.G 1594C

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Scheme 87

Note. Ignore -2-.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Scheme 88

Tape V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis Ground (GND) with an adapter cable from the V.A.G 1594C.

Route V.A.G 1348/3A toward front in engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Scheme 89

Release the retainer -arrow A- and open the cover -arrow B-.

Scheme 90

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Press the button of the remote control.

1. Running noise of pump must be audible.

Note. Because the fuel pump runs quietly, avoid ambient noise during the test.

When the operating noise is no longer audible, remove the fuel delivery unit. Refer to FUEL DELIVERY .

Scheme 91

Check the electrical wires between the locking flange and the fuel pump to make sure they are connected and routed correctly.

If no fault is detected in the electrical wires, replace the fuel delivery unit.

Install the fuel delivery unit INSTALLING while following the information on connecting the battery.

ELECTRIC FUEL PUMP, CHECKING, A5 FROM MY 2012, A4 FROM MY 2013

Check the electric fuel pump in the Guided Fault Finding mode vehicle diagnostic tester.

FUEL PUMP CONTROL MODULE -J538-, CHECKING

1. On vehicles with the FSI engine, the fuel pump is supplied with voltage via the Fuel Pump (FP) control module -J538-.
2. FP Control Module -- testing occurs in Guided Fault Finding operating mode.

FUEL PRESSURE AND RESIDUAL PRESSURE, CHECKING FOR A5 THROUGH 2011, A4 THROUGH MY 2012

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
3. Connector Test Set V.A.G 1594C
4. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear seat bench. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Scheme 92

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

2. Tape adapter cable connector terminal V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis ground with an adapter cable from the V.A.G 1594C.

Route V.A.G 1348/3A toward front in engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -item A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Scheme 93

Remove the fuel filler cap -arrow-.

Scheme 94

Pull the release ring -1- and disconnect the fuel line -2

Connect the VAS 6550 and hose VAS 6550/2 to the fuel supply line.

Scheme 95

Connect the hose VAS 6550/1 and hold it inside a fuel resistant container.

Scheme 96

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Press the switch for the remote control and slowly close the shut-off valve for the pressure gauge.

If the fuel flows without bubbles, close the drain -B-, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the VAS 6550

1. Specified value: 5.0 to 8.0 bar (72 to 116 psi).

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL PRESSURE, RESIDUAL PRESSURE AND FUEL DELIVERY RATE, CHECKING, VEHICLES WITH 4-CYLINDER ENGINES .

Checking Holding Pressure

Watch the pressure fall on the VAS 6550 while checking the holding pressure and checking for leaks

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the holding pressure drops below 3 bar (43.51 psi)

1. Check the connection between the VAS 6550 and the fuel supply line for leaks.
2. Check VAS 6550 for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Repeat the residual pressure check.

If there are still leaks

1. There is a leak at the check valve in the fuel pump: Replace the fuel delivery unit. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Assemble in reverse order of disassembling. Note the following

1. The ignition must be off.

Note. Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before to removing the pressure gauge for the fuel pressure.

Remove the VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL PRESSURE AND RESIDUAL PRESSURE, CHECKING, A5 FROM MY 2012, A4 FROM MY 2013

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Vehicle Diagnostic Tester
3. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Scheme 97

Press the release ring and disconnect the fuel line -2-.

Note. Ignore -1-.

Connect the VAS 6550 and hose VAS 6550/2 to the fuel supply line.

Connect the hose VAS 6550/1 and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Connect the vehicle diagnosis tester.

Turn on the ignition and select the following menu items on the vehicle diagnosis tester

1. OBD
2. Engine Electronics
3. Basic Setting
4. Empty Fuel Tank

Press Start : The fuel pump starts.

If the fuel flows without bubbles, close the drain -B-, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the VAS 6550

1. Specified value: 5.0 to 8.0 bar (72 to 116 psi).

Press the Stop button.

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL DELIVERY RATE, CHECKING, A5 THROUGH MY 2011, A4 THROUGH MY 2012 .

Checking holding pressure

Watch the pressure fall on the VAS 6550 while checking the holding pressure and checking for leaks

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the holding pressure drops below 3 bar

1. Check the connection between the VAS 6550 and the fuel supply line for leaks.
2. Check VAS 6550 for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Repeat the residual pressure check.

If there are still leaks

1. There is a leak at the check valve in the fuel pump: Replace the fuel delivery unit «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Assemble in reverse order of disassembling. Note the following

1. The ignition must be off.

Note. Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before to removing the pressure gauge for the fuel pressure.

Remove the pressure tester VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

Scheme 98

Special tools and workshop equipment required

1. Pressure gauge K-Jetronic V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1 from Adapter for VAG 1318 V.A.G 1318/17
4. Double connection V.A.G 1318/23
5. Remote Control V.A.G 1348/3A with adapter cable V.A.G 1348/3-3
6. Connector test set V.A.G 1594C
7. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear seat bench. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Connect the remote control for V.A.G 1348 V.A.G 1348/3A using the adapter V.A.G 1348/3-3 and cable from the connector test set V.A.G 1594C to the terminal -1-.

2. Tape adapter cable connector terminal V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis ground with an adapter cable from the connector test kit V.A.G 1594C.

Route VAG 1348 Remote Control V.A.G 1348/3A toward front in engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -item A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Pull the release ring -1- and disconnect the fuel line -2

Attach Fuel Line Feed Adapter V.A.G 1318/23 and adapter V.A.G 1318/17-1 to Fuel Inj. Pressure Gauge-CIS V.A.G 1318.

Scheme 99

Install the adapter V.A.G 1318/17-1 on the disconnected fuel supply line.

Attach Adapter V.A.G 1318/11 to Fuel injection. Pressure Gauge-CIS V.A.G 1318.

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open the shut-off valve on the pressure gauge.

1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch on the remote control and slowly closing the shut-off valve on the pressure gauge.

1. Specified value: 4 bar positive pressure.

From this point on do not move position of shut-off valve.

Empty measuring container.

Press the remote control switch for 15 seconds.

Scheme 100

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15 s).

Note. Voltage at fuel pump with engine stopped and pump running is approximate. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assemble in reverse order of disassembling. Note the following

Remove the pressure gauge K-Jetronic V.A.G 1318 and the hose lines.

Install the right locking flange cover (Scheme 79).

Install the rear seat bench. Refer to Remote Control Unlock Handle .

FUEL DELIVERY RATE, CHECKING, A5 FROM MY 2012, A4 FROM MY 2013

Special tools and workshop equipment required

Scheme 101

1. Pressure tester VAS 6550 with hoses VAS 6550/1 and VAS 6550/2
2. Vehicle tester
3. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Pull the release ring -1- and disconnect the fuel line -2

Connect the pressure tester VAS 6550 and hose line VAS 6550/2 to the fuel supply line.

Connect the hose line VAS 6550/1 and hold it inside a fuel resistant container.

Open the drains -A- and -B-.

1. The levers point in the direction of flow.

Connect the tester.

Turn on the ignition and select the following menu items on the Vehicle Diagnosis Tester

1. OBD
2. Engine Electronics
3. Basic Setting
4. Empty Fuel Tank

Note. In order to measure the fuel delivery rate, there must be an initial pressure inside the fuel line against which the fuel pump must work during the measuring. Adjust the initial pressure using pressure tester VAS 6550 as follows

Press Start and create an initial pressure in the fuel system: the fuel pump starts to run and slowly close the shut-off valve -B- on the pressure tester.

1. Specified value: 4.3 bar positive pressure.

From this point on do not move position of shut-off valve.

Press the Stop button.

Empty measuring container.

To measure, press the Start button again and let the fuel pump run for 15 seconds.

After 15 seconds, press the Stop button.

Check the amount of fuel in the measuring container.

1. Specified value: Minimum delivery rate 800 cm 3 /15 s.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assemble in reverse order of disassembling. Note the following

Remove the pressure tester VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL PRESSURE AND RESIDUAL PRESSURE, CHECKING, VEHICLES WITH FSI ENGINES OR TFSI ENGINES THROUGH MY 2012

Special tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Adapter V.A.G 1318/10-12 and Adapter V.A.G 1318/15
3. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
4. Connector Test Set V.A.G 1594C
5. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear seat bench. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis ground with an adapter cable from the V.A.G 1594C.

Route V.A.G 1348/3A toward front in engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the air duct -arrows-.

Scheme 102

Remove the vacuum hose -3- from the connection on the air guide pipe.

Scheme 103

Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Note. Ignore -1 and 2-.

Disconnect the vacuum line -1-.

Scheme 104

Remove the air filter housing and, if applicable, disconnect the electrical connector -2- on the rear side at the intake air switch-over valve -N335-.

Scheme 105

Remove the fuel supply line from the high pressure pump -arrow-.

Connect the V.A.G 1318 with the V.A.G 1318/11 and V.A.G 1318/15 in the fuel line.

Scheme 106

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open the shut-off valve on the pressure gauge.

1. The lever points in the direction of flow.

Press the switch for the remote control and slowly close the shut-off valve for the pressure gauge.

If the fuel flows without bubbles, close the drain, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the V.A.G 1318

1. Specified value: 5.0 to 8.0 bar (72 to 116 psi).

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL DELIVERY RATE, CHECKING, VEHICLES WITH FSI ENGINES OR TFSI ENGINES THROUGH MY 2012 .

Checking Holding Pressure

Check for leaks and constant pressure. Watch the V.A.G 1318 for a drop in pressure while doing this

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the holding pressure drops below 3 bar

1. Check the connections between the V.A.G 1318 and the fuel supply line for leaks.
2. Check the V.A.G 1318 for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Repeat the residual pressure check.

If there are still leaks

1. There is a leak at the check valve in the fuel pump: Replace the fuel delivery unit, refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Assemble in reverse order of disassembling. Note the following

1. The ignition must be off.

Note. Decrease the fuel pressure by opening the drain and letting the fuel run into the measuring container before removing the pressure gauge.

Remove the pressure gauge K-Jetronic V.A.G 1318 and the hose lines.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL DELIVERY RATE, CHECKING, VEHICLES WITH FSI ENGINES OR TFSI ENGINES THROUGH MY 2012

Special tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Adapter V.A.G 1318/10-12 and Adapter V.A.G 1318/15
3. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
4. Connector Test Set V.A.G 1594C
5. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis Ground (GND) with an adapter cable from the V.A.G 1594C.

Route V.A.G 1348/3A toward the front in the engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the air duct -arrows-.

Remove the vacuum hose -3- from the connection on the air guide pipe.

Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Note. Ignore -1 and 2-.

Disconnect the vacuum line -1-.

Remove the air filter housing and, if applicable, disconnect the electrical connector -2- on the rear side at the intake air switch-over valve -N335-.

Remove the fuel supply line from the high pressure pump -arrow-.

Connect the fuel injection pressure gauge V.A.G 1318 with the adapters V.A.G 1318/11 and V.A.G 1318/15 in the fuel line.

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open the shut-off valve on the pressure gauge.

1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch on the remote control and slowly closing the shut-off valve on the pressure gauge.

1. Specified value: 4 bar (58 psi) positive pressure.

From this point on do not move position of shut-off valve.

Empty measuring container.

Press the remote control switch for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15 s).

Note. Voltage at the fuel pump with engine stopped and pump running is approximate. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assemble in reverse order of disassembling. Note the following

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Remove the V.A.G 1318 and the hose lines.

Install the right locking flange cover. (Scheme 79)

Install the rear bench seat. Refer to Remote Control Unlock Handle .

Install the air filter housing. Refer to Removal and Installation .

FUEL PRESSURE AND RESIDUAL PRESSURE, CHECKING, A5 WITH TFSI ENGINE FROM MY 2012, A4 WITH TFSI ENGINE FROM MY 2013

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Vehicle Diagnostic Tester
3. Measuring container, fuel-resistant

Procedure

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Follow all test requirements. Refer to TEST CONDITIONS .

Scheme 107

Remove the fuel supply line from the retainer.

Pull the release button to disconnect the fuel supply line -1-.

Note. Ignore -arrows-.

Connect the VAS 6550 and VAS 6550/2 to the fuel supply line.

Scheme 108

Connect the VAS 6550/1 and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Connect the tester.

Turn on the ignition and select the following menu items on the vehicle diagnosis tester

1. OBD
2. Engine Electronics
3. Basic Setting
4. Empty Fuel Tank

Press Start : The fuel pump starts.

If the fuel flows without bubbles, close the drain -B-, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the VAS 6550

1. Specified value: 5.0 to 8.0 bar (72 to 116 psi).

Press the Stop button.

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL DELIVERY RATE, CHECKING, A5 WITH TFSI ENGINE FROM MY 2012, A4 WITH TFSI ENGINE FROM MY 2013 .

Checking Holding Pressure

Watch the pressure fall on the VAS 6550 while checking the holding pressure and checking for leaks

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the holding pressure drops below 3 bar

1. Check the connection between the VAS 6550 and the fuel supply line for leaks.
2. Check VAS 6550 for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Repeat the residual pressure check.

If there are still leaks

1. There is a leak at the check valve in the fuel pump: Replace the fuel delivery unit, refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Assemble in reverse order of disassembling. Note the following

1. The ignition must be off.

Note. Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before to removing the pressure gauge for the fuel pressure.

Remove the VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL DELIVERY RATE, CHECKING, A5 WITH TFSI ENGINE FROM MY 2012, A4 WITH TFSI ENGINE FROM MY 2013

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Vehicle Diagnostic Tester
3. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Pull the release ring -1- and disconnect the fuel line -2

Connect the VAS 6550 and VAS 6550/2 to the fuel supply line.

Connect the VAS 6550/1 and hold it inside a fuel resistant container.

Open the drains -A and B-.

1. The levers point in the direction of flow.

Connect the tester.

Turn on the ignition and select the following menu items on the Vehicle Diagnosis Tester

1. OBD
2. Engine Electronics
3. Basic Setting
4. Empty Fuel Tank

Note. In order to measure the fuel delivery rate, there must be an initial pressure inside the fuel line against which the fuel pump must work during the measuring. Adjust the initial pressure using VAS 6550 as follows

Press Start and create an initial pressure in the fuel system: the fuel pump starts to run and slowly close the shut-off valve -B- on the pressure tester.

1. Specified value: 4.3 bar (62.36 psi) positive pressure.

From this point on do not move position of shut-off valve.

Press the Stop button.

Empty measuring container.

To measure, press the Start button again and let the fuel pump run for 15 seconds.

After 15 seconds, press the Stop button.

Check the amount of fuel in the measuring container.

1. Specified value: Minimum delivery rate 800 cm 3 /15 s.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assemble in reverse order of disassembling. Note the following

Remove the VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL PRESSURE AND RESIDUAL PRESSURE, CHECKING, S5 THROUGH MY 2011

Special tools and workshop equipment required

1. Pressure Gauge K-Jetronic V.A.G 1318
2. Adapter V.A.G 1318/10-12 and Adapter V.A.G 1318/15
3. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
4. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis Ground (GND) with an adapter cable from the V.A.G 1594C.

Route V.A.G 1348/3A toward the front in the engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the engine cover -arrows-.

Scheme 109

Scheme 110

Disconnect the fuel line -arrow-.

Connect the V.A.G 1318 with the V.A.G 1318/11 and V.A.G 1318/12 in the fuel line.

Scheme 111

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open the shut-off valve on the pressure gauge.

1. The lever points in the direction of flow.

Press the switch for the remote control and slowly close the shut-off valve for the pressure gauge.

If the fuel flows without bubbles, close the drain, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the V.A.G 1318

1. Specified value: 5.0 to 8.0 bar (72 to 116 psi).

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL DELIVERY RATE, CHECKING, S5 THROUGH MY 2011 .

Checking Holding Pressure

Check for leaks and constant pressure. Watch the V.A.G 1318 for a drop in pressure while doing this

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the holding pressure drops below 3 bar

1. Check the connections between the V.A.G 1318 and the fuel supply line for leaks.
2. Check the V.A.G 1318 for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Repeat the residual pressure check.

If there are still leaks

1. There is a leak at the check valve in the fuel pump: Replace the fuel delivery unit «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Assemble in reverse order of disassembling. Note the following

1. The ignition must be off.

Note. Decrease the fuel pressure by opening the drain and letting the fuel run into the measuring container before removing the pressure gauge.

Remove the V.A.G 1318 and the hose lines.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL DELIVERY RATE, CHECKING, S5 THROUGH MY 2011

Special tools and workshop equipment required

1. Pressure gauge K-Jetronic V.A.G 1318
2. Adapter V.A.G 1318/10-12 and Adapter V.A.G 1318/15
3. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
4. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Note. Ignore -2-.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis Ground (GND) with an adapter cable from the connector test kit V.A.G 1594C.

Route V.A.G 1348/3A toward front in engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the engine cover -arrows-.

Disconnect the fuel line -arrow-.

Connect the V.A.G 1318 with the adapters V.A.G 1318/11 and V.A.G 1318/12 in the fuel line.

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open the shut-off valve on the pressure gauge.

1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch on the remote control and slowly closing the shut-off valve on the pressure gauge.

1. Specified value: 4 bar (58 psi) positive pressure.

From this point on do not move position of shut-off valve.

Empty measuring container.

Press the remote control switch for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15 s).

Note. Voltage at fuel pump with engine stopped and pump running is approximate. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assemble in reverse order of disassembling. Note the following

Remove the V.A.G 1318 and the hose lines.

Attach the fuel line to the fuel rail .

Install the right locking flange cover. (Scheme 79)

Install the rear bench seat. Refer to Remote Control Unlock Handle .

FUEL PRESSURE AND RESIDUAL PRESSURE, CHECKING, RS5 THROUGH MY 2011

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
3. Connector Test Set V.A.G 1594C
4. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Note. Ignore -2-.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect the connector terminal -5- to the chassis Ground (GND) with an adapter cable from the V.A.G 1594C.

Route V.A.G 1348/3A toward front in engine compartment.

Remove the center plenum chamber cover. Refer to Removal and Installation .

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the engine cover -arrows-.

Scheme 112

Scheme 113

Disconnect the fuel line by first folding the boot -1- downward.

First push the hose coupling -2- downward -arrow A-, then press the release buttons -arrow B-.

Remove the hose coupling with the release buttons pressed.

Connect the VAS 6550 and VAS 6550/2 to the fuel supply line.

Scheme 114

Connect the hose VAS 6550/1 and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Read the fuel pressure on the VAS 6550

1. Specified value: 5.0 to 8.0 bar (72 to 116 psi).

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL DELIVERY RATE, CHECKING, RS5 THROUGH MY 2011 .

Checking Holding Pressure

Watch the pressure fall on the VAS 6550 while checking the holding pressure and checking for leaks

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the holding pressure drops below 3 bar (43 psi)

1. Check the connection between the VAS 6550 and the fuel supply line for leaks.
2. Check pressure tester VAS 6550 for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Repeat the residual pressure check.

If there are still leaks

1. There is a leak at the check valve in the fuel pump: Replace the fuel delivery unit, refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Assemble in reverse order of disassembling. Note the following

1. The ignition must be off.

Note. Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before removing the pressure gauge for the fuel pressure.

Remove the VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL DELIVERY RATE, CHECKING, RS5 THROUGH MY 2011

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Remote Control V.A.G 1348/3A with Remote Control for VAG 1348 V.A.G 1348/3-3
3. Connector Test Set V.A.G 1594C
4. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Note. Ignore -2-.

Remove the cover -1- on the handle -arrow-.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect connector terminal -5- with an adapter cable from V.A.G 1594C to chassis Ground (GND).

Route V.A.G 1348/3A toward front in engine compartment.

Release the retainer -arrow A- and open the cover -arrow B-.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the engine cover -arrows-.

Disconnect the fuel line by first folding the boot -1- downward.

First push the hose coupling -2- downward -arrow A-, then press the release buttons -arrow B-.

Remove the hose coupling with the release buttons pressed.

Connect the VAS 6550 and hose VAS 6550/2 to the fuel supply line.

Connect the hose VAS 6550/1 and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Generate pressure in the fuel system by pressing the switch on the remote control and slowly closing the shut-off valve on the pressure gauge.

1. Specified value: 4 bar positive pressure.

From this point on do not move position of shut-off valve.

Empty measuring container.

Press the remote control switch for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15 s).

Note. Voltage at fuel pump with engine stopped and pump running is approximate. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assemble in reverse order of disassembling. Note the following

Remove the VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

Install the right locking flange cover. (Scheme 79)

Install the rear bench seat. Refer to Remote Control Unlock Handle .

FUEL PRESSURE AND RESIDUAL PRESSURE, CHECKING, RS5 FROM MY 2012, RS4

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Vehicle Diagnostic Tester
3. Measuring container, fuel-resistant

Procedure

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the engine cover -arrows-.

Disconnect the fuel line by first folding the boot -1- downward.

First push the hose coupling -2- downward -arrow A-, then press the release buttons -arrow B-.

Remove the hose coupling with the release buttons pressed.

Connect the VAS 6550 and hose VAS 6550/2 to the fuel supply line.

Connect the hose VAS 6550/1 and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Connect the tester.

Turn on the ignition and select the following menu items on the vehicle diagnostic tester

1. OBD
2. Engine Electronics
3. Basic Setting
4. Empty Fuel Tank

Press Start : The fuel pump starts.

If the fuel flows without bubbles, close the drain -B-, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the VAS 6550

1. Specified value: 5.0 to 8.0 bar (72 to 116 psi).

Press the Stop button.

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL DELIVERY RATE, CHECKING, RS5 FROM MY 2012, RS4 .

Checking Holding Pressure

Watch the pressure fall on the VAS 6550 while checking the holding pressure and checking for leaks

1. After 10 minutes there must be a residual pressure of at least 3 bar (43 psi).

If the holding pressure drops below 3 bar (43 psi)

1. Check the connection between the VAS 6550 and the fuel supply line for leaks.
2. Check VAS 6550 for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Repeat the residual pressure check.

If there are still leaks

1. There is a leak at the check valve in the fuel pump: Replace the fuel delivery unit, refer to «FUEL DELIVERY»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012__fuel-delivery) .

Assemble in reverse order of disassembling. Note the following

1. The ignition must be off.

Note. Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before removing the pressure gauge for the fuel pressure.

Remove the VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL DELIVERY RATE, CHECKING, RS5 FROM MY 2012, RS4

Special tools and workshop equipment required

1. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
2. Vehicle Diagnostic Tester
3. Measuring container, fuel-resistant

Procedure

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Remove the engine cover -arrows-.

Disconnect the fuel line by first folding the boot -1- downward.

First push the hose coupling -2- downward -arrow A-, then press the release buttons -arrow B-.

Remove the hose coupling with the release buttons pressed.

Connect the VAS 6550 and hose VAS 6550/2 to the fuel supply line.

Connect the hose VAS 6550/1 and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Connect the tester.

Turn on the ignition and select the following menu items on the vehicle diagnostic tester

1. OBD
2. Engine Electronics
3. Basic Setting
4. Empty Fuel Tank

Note. In order to measure the fuel delivery rate, there must be an initial pressure inside the fuel line against which the fuel pump must work during the measuring. Adjust the initial pressure using VAS 6550 as follows

Press Start and create an initial pressure in the fuel system: the fuel pump starts to run and slowly close the shut-off valve -B- on the pressure tester.

1. Specified value: 4.3 bar (62 psi) positive pressure.

From this point on do not move position of shut-off valve.

Press the Stop button.

Empty measuring container.

To measure, press the Start button again and let the fuel pump run for 15 seconds.

After 15 seconds, press the Stop button.

Check the amount of fuel in the measuring container.

1. Specified value: Minimum delivery rate 800 cm 3 /15 s.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assemble in reverse order of disassembling. Note the following

Remove the VAS 6550 with hoses VAS 6550/1 and VAS 6550/2.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL LEVEL SENSOR -G-, CHECKING

Special tools and workshop equipment required

1. Multimeter V.A.G 1526D
2. Connector Test Set V.A.G 1594C

Procedure

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connector -1- on the locking flange.

Note. Ignore -2-.

Connect the multimeter to measure the resistance between contacts -2 and 4-.

Scheme 115

Fuel Level Sensor -G- installed

1. Sensor at lower stop: approximately 280 ohms.
2. Sensor at upper stop: approximately 65 ohms.

Note. If measured value is 0 ohms there is a short circuit. If measured value is there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty", the fuel delivery unit must be removed FUEL DELIVERY and the sensor floater must be placed in upper or lower end position. With fuel gauge sender removed, the following values are obtained because of the greater deflection of the floater arm

Fuel Level Sensor -- removed

1. Sensor at lower stop: approximately 288 ohms.
2. Sensor at upper stop: approximately 57 ohms.

Connect the multimeter to measure the resistance between contacts -3 and 4-.

Fuel Level Sensor -- installed or removed

1. Any sensor position: approximately 340 ohms.

Assemble in reverse order of disassembling. Note the following

Install the right locking flange cover. (Scheme 79)

Install the rear bench seat. Refer to Remote Control Unlock Handle .

FUEL LEVEL SENSOR 2 -G169-, CHECKING

Special tools and workshop equipment required

1. Multimeter V.A.G 1526D
2. Connector Test Set V.A.G 1594C

Procedure

Note. The electric wires for fuel level sensor 2 -- are routed to the fuel pump locking flange inside the fuel tank.

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connectors -1 and 2- -2- on the locking flange.

Connect the multimeter for the resistance measurement between terminal -2- on the connector -A- and terminal -2- on the connector -B-.

Scheme 116

Fuel level sensor 2 -- installed

1. Sensor at lower stop: approximately 290 ohms.
2. Sensor at upper stop: approximately 45 ohms.

Note. If measured value is 0 ohms there is a short circuit. If measured value is there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty", the fuel level sensor 2 -G169- must be removed. Refer to Fuel Level Sensor 2 -G169 and the sensor floater must be placed in the upper or lower end position. With fuel gauge sensor removed, the following values are obtained because of the greater deflection of the floater arm

Fuel level sensor 2 -- removed

1. Sensor at lower stop: approximately 290 ohms.
2. Sensor at upper stop: approximately 16 ohms.

Connect the multimeter between terminals -1 and 2- on connector -A- to measure the resistance.

Fuel level sensor 2 -- installed or removed

1. Any sensor position: approximately 340 ohms.

Assemble in reverse order of disassembling. Note the following

Install the right locking flange cover. (Scheme 79)

Install the rear bench seat. Refer to Remote Control Unlock Handle .

LEAK DETECTION TEST, PERFORMING

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094
2. Vehicle Diagnostic Tester

Diagnostic leak test occurs in Guided Fault Finding vehicle diagnostic tester.

Checking fuel supply and tank ventilation systems for leaks.

Note. The following describes individual areas in the fuel supply and ventilation systems where leaks are possible. After repairing a possible leak, perform a leak test to ensure that leak was successfully repaired.

Turn off the ignition.

Check if the fuel tank locking cap -arrow- was closed completely during the test.

Check whether seal of fuel filler cap was damaged or crimped. Replace if necessary.

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Note. Observe installation notes for locking flanges INSTALLING .

Check if the sealing rings under the locking flanges are OK or if the locking rings on the locking flange are tightened correctly on the fuel tank. Also check the fuel line connections.

Visually check all lines and hose connections on the fuel system and replace leaking lines such as

1. Line from EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80
2. Lines from EVAP canister to leak detection pump -V144-.
3. Line from fuel tank to EVAP canister (below heat shield for EVAP canister).
4. Lines for tank ventilation (beneath right rear wheel housing liner).
5. Fuel lines to engine.

Note. Leaks at lines and components of tank system can sometimes be located using a nonflammable, environmentally compliant leak detection spray. For this, initiate leak diagnostic several times in sequence to build up pressure in the system. At leaking areas, bubbles will form.

Perform a visual inspection on the fuel system components and tank ventilation system

1. Fuel Tank
2. EVAP Canister
3. Leak detection pump -V144
4. EVAP canister purge regulator valve 1 -N80

Note. Due to the form or function of the components, leaking areas may not always be localized by spraying on leak detection spray. It may be necessary to clamp off the relevant component using 3094 and initiate tank leak detection diagnostic. If the leak is no longer indicated, the component that was clamped off is defective. If clamped off directly at the leak detection pump and a leak is still indicated, the leak detection pump itself is leaking.

FUEL TANK WITH ATTACHMENTS

Special tools and workshop equipment required

1. Engine-/Gearbox Jack V.A.G 1383 A

REMOVING

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Disconnect the battery. Refer to Removal and Installation .

Drain the fuel tank. Refer to FUEL TANK, DRAINING .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connectors -1 and 2- on the locking flange.

Open the fuel filler door.

Clean the area around the fuel filler tube.

Remove the locking cap -arrow- from the fuel filler tube.

Note. To prevent dirt from entering the fuel tank, seal the opening with a clean foam piece.

Remove the right rear wheel. Refer to Removal and Installation .

Remove right rear wheel housing liner. Refer to Removal and Installation .

Remove fuel filler tube bolts -1 and 2-.

Remove the rear section of the exhaust system. Refer to [For engine(s) CAUA] Description and Operation .

Remove the rear axle. Refer to Removal and Installation .

Scheme 117

Press the release button and disconnect the right front fuel line -1- from the fuel tank.

Disconnect the vent line -1- on the left of the Evaporative Emission (EVAP) canister by pressing the release button.

Scheme 118

Place the V.A.G 1383 A under the fuel tank for support.

Scheme 119

Support fuel tank using the V.A.G 1383 A.

Scheme 120

Remove bolts -1 through 5- and remove the accessory assembly bracket -6-.

Lower the fuel tank with the V.A.G 1383 A while guiding it by hand.

INSTALLING

1. Tightening specification, refer to «FUEL TANK WITH ATTACHMENTS OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Install in reverse order of removal. Note the following

Make sure the fuel and vent lines are clipped to the fuel tank properly.

Position the fuel tank with the mounting strap and carrier plate on the vehicle underbody using the V.A.G 1383 A.

Make sure the fuel tank is positioned so that the filler tube can be guided into the opening of the body correctly.

Install the exhaust system bracket -6- and tighten the mounting strap and carrier plate bolts -1 through 5-.

Make sure the filler tube threaded connections -1- and -2- are free of corrosion so the ground connection to the body is not affected.

Tighten the fuel filler tube bolts -1 and 2-.

Install the rear axle. Refer to Removal and Installation .

Install the rear section of the exhaust system. Refer to [For engine(s) CAUA] Description and Operation .

Install the right rear wheel housing liner. Refer to Removal and Installation .

Mount the rear wheel. Refer to Removal and Installation .

Install the right locking flange cover. (Scheme 79)

Install the rear bench seat. Refer to Remote Control Unlock Handle .

Connect the battery. Be sure to read the procedures after connecting the battery. Refer to Removal and Installation .

FUEL PUMP CONTROL MODULE -J538

Special tools and workshop equipment required

1. Fuel Tank Sender Unit Tool T40068 A

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Empty the fuel tank if necessary. Refer to FUEL TANK, DRAINING .

Move the passenger seat all the way forward if necessary.

Disconnect the battery. Refer to Removal and Installation .

Remove the rear seat bench. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connectors -1 and 2- on the locking flange.

Scheme 121

If necessary, disengage the electrical connector -3- to the auxiliary heater metering pump at the locking flange and lay it aside.

Scheme 122

Disconnect the fuel line -2- at the locking flange by pressing the release button.

If necessary, disconnect the fuel line -1- to the auxiliary heater metering pump at the locking flange by pressing the release button.

Scheme 123

Use a T40068 A to remove the union nut -arrow-.

Note. When union nut is loosened, plastic catch on threaded ring breaks off - ignore.

Cover the fuel tank opening with a clean cardboard box -1- to prevent dirt from falling into it.

Scheme 124

Remove the bolts -arrows-.

Pull the FP control module -- -1- in between the fuel tank and vehicle underbody.

Scheme 125

The control module must be guided between the floor panel and the fuel tank. Sometimes it is necessary to lift the floor panel slightly in order to do this (on case by case basis).

Disconnect the connector and remove the FP control module --.

1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Install in reverse order of removal. Note the following

Note. Replace the sealing ring and the union nut.

Bring the FP control module -- into installation position and tighten it.

Place the union nut -1- on your left arm and push the locking flange -2- forcefully into installation position with your left hand -arrow-.

Scheme 126

1. The tab -4- on locking flange must lie between tabs -3 and 5- on threaded ring.

Slide the union nut -1- off your left arm using your right hand while your left hand keeps holding the locking flange -2- down firmly -arrow-.

Scheme 127

Position the union nut -1- with your right hand so the double ridge -5- on the ribs is over the lug -3- on the locking flange (approximately "10 o'clock" position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it -4-.

Press the locking flange down firmly with a screwdriver -arrow-.

Scheme 128

Turn the union nut approximately 480° with your right hand until the double ridge -1- is in approximately "2 o'clock position" while keeping the locking flange pressed down firmly with your left hand.

Scheme 129

Tighten the union nut using T40068 A.

Scheme 130

1. Verification: The double ridge -1- must now be between "7 and 8 o'clock".

Connect fuel lines -1 and 2-.

Connect the connectors.

Install the right locking flange cover.. (Scheme 79).

Install the rear seat bench. Refer to Remote Control Unlock Handle .

Connect the battery. Be sure to read the procedures after connecting the battery. Refer to Removal and Installation .

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

FUEL DELIVERY

Special tools and workshop equipment required

1. Fuel Tank Sender Unit Tool T40068 A

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Empty the fuel tank if necessary, refer to FUEL TANK, DRAINING .

Move the passenger seat all the way forward if necessary.

Disconnect the battery. Refer to Removal and Installation .

Remove the rear bench seat. Refer to Remote Control Unlock Handle .

Remove the locking flange cover -arrows-.

Disconnect the connectors -1 and 2- on the locking flange.

If necessary, disengage the electrical connector -3- to the auxiliary heater metering pump at the locking flange and lay it aside.

Disconnect the fuel line -2- at the locking flange by pressing the release button.

If necessary, disconnect the fuel line -1- to the auxiliary heater metering pump at the locking flange by pressing the release button.

Use a T40068 A to remove the union nut -arrow-.

Note. When union nut is loosened, plastic catch on threaded ring breaks off - ignore.

Remove the locking flange -2- with fuel filter from the fuel tank and tip it slightly to the left side of the vehicle.

Scheme 131

Remove the seal -1-.

Pull the locking flange with fuel filter away from the fuel delivery unit slightly -arrow A-.

At the same time, tilt the locking flange with fuel filter out of the fuel tank -B arrows-, being especially careful of the retaining plate with the ground connection -3- and the fuel line -4-.

Scheme 132

Pull the locking flange -2- with fuel filter away from the fuel delivery unit -1- slightly again -arrow A-.

Tilt the fuel delivery unit to the left side of the vehicle -arrow B- and pull it out of the fuel tank slightly.

Note. When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor --.

Remove the fuel level sensor -- -3- from the fuel tank opening.

Remove the suction line -3- by pressing the release -1-.

Scheme 133

Disconnect the connector -2- for the fuel level sensor 2 -G169- by pressing the release -arrow-.

Note. The illustration shows the fuel delivery unit with the fuel tank.

1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Install in reverse order of removal. Note the following

Note. Replace the sealing ring and the union nut. When inserting the fuel delivery unit, do not bend the floater arm on the fuel level sensor --. Make sure the fuel hoses are secure.

Guide the suction line -3- out of the fuel tank and connect it until it engages audibly.

Connect the electrical connector -2- for the fuel level sensor 2 --.

Make sure the Ground (GND) wire -arrow- is connected securely to the fuel pressure regulator retaining plate.

Scheme 134

Insert the fuel level sensor -- -3- in the fuel tank.

Scheme 135

Pull the locking flange -2- with fuel filter away from the fuel delivery unit -1- slightly again -arrow A-.

Bend the fuel delivery unit to the left side of the vehicle and tilt it into the fuel tank -arrow B- while being careful of the fuel level sensor -3-.

Pull the locking flange -2- with the fuel filter away from the fuel delivery unit slightly -arrow A-.

Scheme 136

At the same time, tilt the locking flange with fuel filter into the fuel tank -B arrows-, being especially careful of the retaining plate with the ground connection -3- and the fuel line -4-.

Stretch the new sealing ring -1- over the locking flange and insert it in the groove on the fuel tank.

Place the union nut -1- on your left arm and push the locking flange -2- forcefully into installation position with your left hand -arrow-.

1. The tab -4- on locking flange must lie between tabs -3 and 5- on threaded ring.

Slide the union nut -1- off your left arm using your right hand while your left hand keeps holding the locking flange -2- down firmly -arrow-.

Position the union nut -1- with your right hand so the double ridge -5- on the ribs is over the lug -3- on the locking flange (approximately "10 o'clock" position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it -4-.

Press the locking flange down firmly with a screwdriver -arrow-.

Turn the union nut approximately 480° with your right hand until the double ridge -1- is in approximately "2 o'clock position" while keeping the locking flange pressed down firmly with your left hand.

Tighten the union nut using T40068 A.

1. Verification: The double ridge -1- must now be between "7 and 8 o'clock".

Connect fuel lines -1 and 2-.

Connect the connectors.

Install the right locking flange cover (Scheme 79).

Install the rear bench seat. Refer to Remote Control Unlock Handle .

Connect the battery. Be sure to read the procedures after connecting the battery. Refer to Removal and Installation .

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

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Note. During installation, the cable ties must be installed at the same location.

Remove the fuel delivery unit. Refer to FUEL DELIVERY .

Disconnect the connector -4- by pressing the release -arrow-.

Scheme 137

Cut through the cable ties -2- and free up the electrical connector.

Release the retaining tabs -1 and 3- and remove the fuel level sensor -- upward.

Install in reverse order of removal. Note the following

Insert the fuel level sensor -- in the guides on the fuel delivery unit and push down until it engages.

Connect the connector. Make sure it is secure.

Install the fuel delivery unit INSTALLING while following the information on connecting the battery.

FUEL LEVEL SENSOR 2 -G169

Special tools and workshop equipment required

1. Window Cutter V.A.G 1561A
2. Blade (L-shaped, 25.4 mm) V.A.G 1561/22 V.A.G 1561/22
3. Fuel Tank Sender Unit Tool T40068 A
4. Sealant

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Empty the fuel tank if necessary, refer to FUEL TANK, DRAINING .

Disconnect the battery. Refer to Removal and Installation .

Fold the rear bench seat backrest forward.

A4 Sedan, A5 Cabrio and Coupe

Remove the loading aid frame. Refer to Removal and Installation .

A4 Avant

Remove the front luggage compartment floor (vehicle tool box). Refer to Removal and Installation .

All Vehicles

Scheme 138

Cut through the sealing around the locking flange cover with the V.A.G 1561A and V.A.G 1561/22.

Remove the locking flange cover.

Repair damaged painted surfaces.

Apply corrosion protection if necessary.

Disconnect the vent lines -1, 2 and 3- on the locking flange by pressing the release buttons.

Scheme 139

Scheme 140

Use a T40068 A to remove the union nut -arrow-.

Note. When union nut is loosened, plastic catch on threaded ring breaks off - ignore.

Carefully remove the fuel level sensor 2 -- -3- from the fuel tank opening.

Scheme 141

Note. When removing, be sure not to bend floater arm of fuel level sensor 2 --.

Disconnect the connector -2- by pressing the release -arrow A-.

Press the bracket together with needle nose pliers -B arrows- and remove the suction line -1-.

1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Install in reverse order of removal. Note the following

Note. Replace the sealing ring and the union nut.

Install the suction line -1- until it engages audibly.

Connect the electrical connector -2- and make sure it engages.

Note. When inserting, be sure not to bend floater arm on fuel level sensor 2 --.

Carefully insert the fuel level sensor 2 -- -3- in the fuel tank opening.

Stretch the new sealing ring over the locking flange and insert it in the groove on the fuel tank.

Place the union nut -1- on your left arm and push the locking flange -2- forcefully into installation position with your left hand -arrow-.

Scheme 142

1. The tab -4- on locking flange must lie between tabs -3 and 5- on threaded ring.

Slide the union nut -1- off your left arm using your right hand while your left hand keeps holding the locking flange -2- down firmly -arrow-.

Scheme 143

Position the union nut -1- with your right hand so the double ridge -5- on the ribs is over the lug -3- on the locking flange (approximately "10 o'clock" position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it -4-.

Press the locking flange down firmly with a screwdriver -arrow-.

Scheme 144

Turn the union nut approximately 480° with your right hand until the double ridge -1- is in approximately "2 o'clock position" while keeping the locking flange pressed down firmly with your left hand.

Scheme 145

Tighten the union nut using T40068 A.

Scheme 146

1. Verification: The double ridge -1- must now be between "7 and 8 o'clock".

Shortly before installing the locking flange cover, smooth out the rest of the sealant on the cover and on the body with a carpet knife but do not remove it completely.

Note. The remaining material acts as an adhesive base for the new sealant that will be applied.

Cut the sealant cartridge nozzle as shown in the illustration.

Scheme 147

1. Dimension -a- = 7 mm.

Apply a new sealant bead to the smoothed sealant on the locking flange cover and insert the cover.

1. The arrow on the cover must point in the direction of travel.

Install the loading aid frame. Refer to Removal and Installation .

Connect the battery. Be sure to read the procedures after connecting the battery. Refer to Removal and Installation .

After installing the fuel level sensor 2 --, fill the vehicle with at least 5 liters (5.28 quarts) of fuel.

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Remove the fuel delivery unit. Refer to FUEL DELIVERY .

Remove the fuel level sensor 2 -G169-. Refer to Fuel Level Sensor 2 -G169 .

Carefully remove the fuel level sensor 2 -- -3- with the suction line -1- from the fuel tank opening.

Note. When removing, be sure not to bend floater arm of fuel level sensor 2 --.

Disconnect the connector -2- by pressing the release -arrow A-.

Press the bracket together with needle nose pliers -B arrows- and remove the suction line.

Scheme 148

Install in reverse order of removal. Note the following

Prepare the suction line for installation -6

1. The electrical connector -5- must be clipped onto the suction line -6- as shown in the illustration.
2. The electrical wires -2- and the suction line must be secured with a total of 7 cable ties -3, 4, 7 and 8-.
3. The O-ring -1- must be installed on the suction line.

Install the suction line -1- until it engages audibly.

Connect the electrical connector -2- and make sure it engages.

Note. When inserting, do not bend the floater arm on the fuel level sensor 2 -- -3-.

Slide the suction line from the luggage compartment into the fuel tank opening.

Stretch the new sealing ring over the locking flange and insert it in the groove on the fuel tank.

Reach into the front fuel tank opening and pull the suction line into the installation position.

Install fuel level sensor 2, refer to INSTALLING .

Install the fuel delivery unit, refer to INSTALLING .

Connect the battery. Be sure to read the procedures after connecting the battery. Refer to Removal and Installation .

After installing the suction line, fill the vehicle with at least 5 liters 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.

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Remove the fuel delivery unit. Refer to FWD FUEL DELIVERY , AWD FUEL DELIVERY .

Disconnect the Ground (GND) connection -arrow- on the fuel pressure regulator retaining plate.

Remove the fuel line -1- by pressing the release button.

Scheme 149

Disconnect the connector -6- for the fuel level sensor G.

Disconnect the fuel pump electrical connector at the fuel pump.

Remove the locking flange -4- with fuel filter upward out of the fuel delivery unit -3-.

Release a total of 3 retaining tabs -5- by sliding 3 release bars -7- (with the fuel filter parts set) -arrow-.

Pull the fuel filter -2- down out of the locking flange.

Install in reverse order of removal. Note the following

Note. Replace the O-ring.

Insert the fuel filter into the guides on the locking flange and press it in until it engages.

Note. The fuel filter can only be inserted in one position.

Install the fuel delivery unit. Refer to FWD FUEL DELIVERY , AWD INSTALLING .

EVAP CANISTER

Note. Checking for leaks, refer to LEAK DETECTION TEST, PERFORMING .

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Remove the left rear underbody panel. Refer to Removal and Installation .

Disconnect the connector -6-.

Scheme 150

Remove the air line -5-.

Remove the vent line -7-.

Disconnect the vent line -9- to the Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- by pressing the release button.

Disconnect the vent line -2- to the fuel tank by pressing the release button.

Remove the bolts -1, 4 and 8- and the EVAP canister -3-.

1. Tightening specification, refer to «EVAPORATIVE EMISSION CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Install in reverse order of removal. Note the following

Connect the air and vent lines until they engage audibly.

Scheme 151

Remove the Evaporative Emission (EVAP) canister. Refer to EVAP CANISTER .

Free up the electrical connector -2-.

Remove the bolts -3-.

Unclip the diagnosis pump -1- from the bracket on the EVAP canister.

1. Tightening specification, refer to «EVAPORATIVE EMISSION CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Install in reverse order of removal. Note the following

Note. Replace the gasket.

Install the EVAP canister. Refer to EVAP CANISTER .

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

Remove the left rear wheel. Refer to Removal and Installation .

Remove the left rear wheel housing liner. Refer to Removal and Installation .

Press the release button and remove the vent line -arrow-.

Scheme 152

Remove the nut -2- and remove the -1- Leak Detection Pump -V144- air filter.

Install in reverse order of removal. Note the following

Tighten the nut for the Leak Detection Pump -V144- air filter. (Scheme 84)

Install the rear left wheel housing liner. Refer to Removal and Installation .

Mount the rear wheel. Refer to Removal and Installation .

ACCELERATOR PEDAL POSITION SENSOR -G79- WITH ACCELERATOR PEDAL POSITION SENSOR 2 -G185

Special tools and workshop equipment required

1. Vehicle Diagnostic Tester

Scheme 153

Remove the lower instrument panel cover on the driver side. Refer to Removal and Installation .

Disconnect the connector -2- by pressing the release -1- up -arrow-.

Remove the bolt -3- and remove the accelerator pedal module downward.

Scheme 154

1. Tightening specification, refer to «ACCELERATOR PEDAL MODULE OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Install in reverse order of removal. Note the following

Engage the accelerator pedal module -4- on the bottom of the pedal bracket -1-, insert the centering pin -2- and tighten the bolt -3-.

Install the lower instrument panel cover on the driver side. Refer to Removal and Installation .

Perform after the first kick-down adaptation in Guided Functions , vehicle diagnostic tester.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

1. Fuel Tank Sender Unit Tool T40068 A
2. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
3. Adapter V.A.G 1318/10-12 and Adapter V.A.G 1318/15
4. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
5. Engine-/Gearbox Jack V.A.G 1383 A
6. Multimeter V.A.G 1526D
7. Window Cutter V.A.G 1561A
8. Blade (L-shaped, 25.4 mm) V.A.G 1561/22
9. Connector Test Set V.A.G 1594C
10. Fuel Siphoning Device VAS 5190
11. Suction Pump VAS 5226
12. Hand Vacuum Pump VAS 6213
13. Pressure Tester VAS 6550 with Hoses VAS 6550/1 and VAS 6550/2
14. Not illustrated
15. Remote Control for VAG 1348 V.A.G 1348/3-3

See also:
• SAFETY PRECAUTIONS
• CLEAN WORKING CONDITIONS
• Removal and Installation
• TEST CONDITIONS
• Remote Control Unlock Handle
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• LEAK DETECTION TEST, PERFORMING
• Accelerator Pedal Position Sensor -G79- WITH Accelerator Pedal Position Sensor 2 -G185
• FUEL TANK WITH ATTACHMENTS
• ELECTRIC FUEL PUMP, CHECKING
• FUEL DELIVERY
• Fuel Pump Control Module -J538
• Fuel Level Sensor 2 -G169-, CHECKING
• Fuel Level Sensor 2 -G169
• Fuel Level Sensor -G-, CHECKING
• EVAP CANISTER
• FUEL DELIVERY RATE, CHECKING, VEHICLES WITH FSI ENGINES OR TFSI ENGINES THROUGH MY 2012
• FUEL DELIVERY RATE, CHECKING, A5 WITH TFSI ENGINE FROM MY 2012, A4 WITH TFSI ENGINE FROM MY 2013
• FUEL DELIVERY RATE, CHECKING, S5 THROUGH MY 2011
• FUEL DELIVERY RATE, CHECKING, RS5 THROUGH MY 2011
• FUEL DELIVERY RATE, CHECKING, RS5 FROM MY 2012, RS4
• FUEL TANK, DRAINING