Fuel Pump Control Module

Fuel Pump Control Module

Removing

Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

CAUTION!
• To lower, fuel tank must be empty for weight reasons. Empty fuel tank if necessary.

CAUTION!
• Observe safety precautions when disconnecting the battery.

All except Audi RS4:

- Push the cover over the battery toward the right - arrow 1 - and remove it upward - arrow 2 -.





- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.





Audi RS4:

- Raise luggage compartment floor covering and secure.

- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.





All:

- Open the tank flap and clean the area around the fuel filler tube.

• Do not remove fuel cap.

- Pry the tensioning ring - arrow - out from rubber gasket and press the rubber gasket through toward the inside.





- Remove right rear wheel.

- Remove right rear wheel housing liner.

- Unfasten bolt - 1 - for fuel filler tube.





• Ignore - 2 -.

- Remove right rear cover - 1 - on bottom of vehicle floor.





CAUTION!
• For weight reasons, fuel tank must be empty when lowering.

- Loosen bolts - 1, 2, 3, 4, 5, 9, 10 - a maximum of 8 turns.





- Remove bolts - 6, 7, 8 -.

- Remove rear seat bench.

- Remove cover - arrows - for right locking flange.





Audi RS4:

- Free up electrical connector - arrow - for Fuel Pump (FP) Control Module (J538) and disconnect.





All:

- Disconnect electrical harness connector - arrow - at locking flange.





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





CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

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

- Remove bolts - arrows -.





- Pull out the Fuel Pump (FP) Control Module (J538 ) between the fuel tank and the vehicle floor.

Installing

Installation is in reverse order of removal, note the following:

- Fasten mounting straps and carrier plate - 1 to 10 -.





- Fasten the fuel filler tube with Ground (GND) connection using bolt - 1 -.





CAUTION!
After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:

• Specified value: Approximately 0 ohms.

• Ignore - 2 -.

- Install right rear wheel housing liner.

- Install rear seat bench.

- Connect battery. Observe safety precautions after connecting battery.

Tightening Specifications