Fuel Pump Control Module - J538-, Removing And Installing, Vehicles With Fwd And AWD: Installing

Install in reverse order of removal. Note The Following:

Tightening specification. Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

NOTE:

Replace the sealing ring and the union nut.

-- Bring the Fuel Pump Control Module -J538- into the 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-.

Fig 1: Place Union Nut On Your Left Arm And Push Locking Flange Forcefully Into Installation Position With Your Left Hand

Courtesy of AUDI OF AMERICA, LLC

The tab -4- on locking flange must be between the tabs -3- and -5- on the 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-.

Fig 2: Press Locking Flange Down Firmly

Courtesy of AUDI OF AMERICA, LLC

-- 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 -arrow-.

Fig 3: Turn Union Nut Approximately 480Degrees With Your Right Hand

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 4: Press the locking flange down firmly when tightening the union nut so it does not rotate too

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

There is a risk of the locking flange threaded connection leaking.

Press the locking flange down firmly when tightening the union nut so it does not rotate too.

-- Tighten the union nut using Fuel Tank Sender Unit Tool:T40068A .

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

Fig 5: Double Ridge -1- Must Now Be Between "7 And 8 O'clock"
Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Connect the connectors.

-- Install the sealing flange cover. Refer to Figure.

-- Install the rear bench seat. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Connect the batter while doing so follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Vehicles with auxiliary heater: To vent the fuel line to the auxiliary heater metering pump, run for 10 minutes at Wide Open Throttle (WOT).