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FUEL PUMP CONTROL MODULE Audi TT 8J

Fuel Supply System (coupe) 14 illustrations ~1012 words

FUEL PUMP CONTROL MODULE

Removing

TT Coupe

Remove rear seat bench. Refer to Removal and Installation .

TT Roadster

Remove the right side rear panel trim panel. Refer to Removal and Installation .

All Vehicles

Remove Fuel Pump (FP) control module -J538- from locking flange cover and disconnect electrical connector -arrow-.

Unclip catches -arrows- of right connector flange cover.

Disconnect the connector -arrow- from the locking flange.

Installing

Install in reverse order, paying attention to the following

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

TT Roadster

Install the right side rear panel trim panel. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Wrench T10202

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

TT Roadster

CAUTIONIt is necessary to remove the fuel tank first in order to be able to remove the fuel delivery unit on the Audi TT Roadster.

Removing fuel tank, refer to FUEL TANK WITH ATTACHMENTS .

TT Coupe

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

Disconnect the battery. Refer to [For transmission(s) 02E] Removal and Installation .

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 3 / 4 full.

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

Remove rear seat bench. Refer to Removal and Installation .

Unclip the retainers -arrows- of the cover for sealing flange.

Disconnect the connector -arrow- from the locking flange.

Mark the fuel supply line -1- and fuel return line -2-.

Scheme 237

Scheme 237
Scheme 237
WARNINGThere is a risk of injury because the fuel is under high pressure. To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

Pull both lines from locking flange, by pressing the release buttons.

TT Roadster

Mark the fuel supply -1- and the fuel return -2- lines on the removed fuel tank.

Pull both lines from locking flange, by pressing the release buttons.

TT Coupe

WARNINGDanger due to escaping fuel. To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 3 / 4 full.

All vehicles

Remove locking ring with T10202.

Remove the fuel delivery unit and seal trough the opening in the fuel tank.

Note. When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-. Be sure there is still some fuel inside the fuel delivery unit.

Installing

  1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR -G- OVERVIEW»(/audi/tt/8j-2006-2010/remont/fuel-system/#fuel-supply-system-coupe) .

Install in reverse order, paying attention to the following

Note. Replace seal. When inserting fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-.

Install the fuel delivery unit into the fuel tank.

Install the new locking flange seal dry.

Scheme 238

Scheme 238
Scheme 238
CAUTIONRisk of leaking. When inserting sealing flange, sealing ring must not be damaged or crushed.

Press locking flange down against spring pressure and bring it into installation position.

  1. The tab -2- on locking flange must lie between tabs -1 and 3- on fuel tank.

Note. Arrow- points in direction of travel.

Tighten locking ring.

TT Coupe

Install rear seat bench. Refer to Removal and Installation .

Connect the battery. Observe safety precautions after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

TT Roadster

Installing fuel tank. Refer to Installing .

All Vehicles

After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.

On vehicles with TFSI engine, with toothed belt drive, a fuel pump adaptation must be performed after replacing the fuel delivery unit. Refer to TOOTHED BELT DRIVE, PERFORMING A FUEL PUMP ADAPTATION AFTER REPLACING FUEL DELIVERY UNIT .

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

TT Roadster

CAUTIONIt is necessary to remove the fuel tank in order to remove the fuel level sensor -G- on the Audi TT Roadster.

Removing the fuel tank, refer to FUEL TANK WITH ATTACHMENTS .

All Vehicles

Install the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Version 1

CAUTIONRisk of damage. Before disconnecting electrical connectors on the fuel level sensor, first release the connector contact retaining tab.

Disconnect the connectors -1 through 3-.

Pry on the retaining tabs -4 and 5- with a screwdriver and pull the fuel level sensor off downward -arrow-.

Version 2

Scheme 239

Scheme 239
Scheme 239

Release the retaining tabs -arrows- with a screwdriver and pull the fuel level sensor upward and out.

Scheme 240

Scheme 240
Scheme 240
CAUTIONRisk of damage. Before disconnecting electrical connectors on fuel level sensor, first release connector contact retaining tab.

Disconnect the connectors -1 through 3-.

Installing

Install in reverse order, paying attention to the following

Version 1

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

Connect the electrical connections -1 through 3- and make sure they are securely engaged.

Version 2

Connect the electrical connections -1 through 3- and make sure they are securely engaged.

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

Continuation for All Versions

Install fuel delivery unit. FUEL DELIVERY UNIT , observing notes for connecting battery.

Scheme 241

Scheme 241: SPECIAL TOOLS
Scheme 241: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
  2. Adapter V.A.G 1318/11
  3. Adapter V.A.G 1318/17-1A
  4. Fuel Line Feed Adapter V.A.G 1318/23
  5. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  6. Connector Test Set V.A.G 1594C

Special tools and workshop equipment required

Scheme 242

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Scheme 245

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Scheme 249

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Scheme 250

Scheme 250
Scheme 250
  1. Remote Control V.A.G 1348/3A with Remote Control V.A.G 1348/3-3
  2. Wrench T10202
  3. Fuel Extracting Device VAS 5190
  4. Multimeter V.A.G 1526D
  5. Connector Test Set V.A.G 1594C
  6. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
  7. Vehicle Diagnostic, Testing, and Information System VAS 5051B
  8. Release Tool T10238
  9. Engine/Transmission Jack V.A.G 1383 A
  10. Hooks 3004
  11. Wrench T10202
  12. Not illustrated
  13. Hose Clamps Up to 25 mm Dia. 3094

See also:
• [For engine(s) CBRA] General Information
• [For engine(s) BPY, CDMA] General Information
• [For transmission(s) 02E] Removal and Installation
• Removal and Installation
• Removal and Installation
• [For engine(s) CBRA] Description and Operation
• [For engine(s) BPY] Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• LEAK DETECTION TEST, PERFORMING
• FUEL TANK, DRAINING
• FUEL TANK, DRAINING
• CLEAN WORKING CONDITIONS
• Fuel Level Sensor 2 -G169
• FUEL PUMP ELECTRICAL, CHECKING
• EVAPORATIVE EMISSION (EVAP) CANISTER
• Leak Detection Pump (LDP) -V144
• FUEL FILTER
• ACCELERATOR PEDAL MODULE, VERSION 1
• ACCELERATOR PEDAL MODULE, VERSION 2
• FUEL TANK WITH ATTACHMENTS
• Fuel Level Sensor -G-, CHECKING
• Fuel Level Sensor -G
• FUEL DELIVERY UNIT
• PRESS LOCKING FLANGE DOWN AGAINST THE SPRING PRESSURE AND BRING IT INTO INSTALLATION POSITION
• FUEL LEVEL SENSOR 2 -G169-, CHECKING
• FUEL PUMP, TESTING ELECTRICALLY
• TEST CONDITIONS
• FUEL FILTER OVERVIEW
• TOOTHED BELT DRIVE, PERFORMING A FUEL PUMP ADAPTATION AFTER REPLACING FUEL DELIVERY UNIT