Service

Workshop Manual
Audi A6 2011 ➤
Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines
CLAB CLAA CDU
Engine ID
CGL CGL CMG CGQ CKV CGL
C C D B B B E
CKV CDU CPN CTC CTC CVU CRT CRT CRT
C D B B C A D E F
CVU CNH CSU CSU CZJA CZV CZV CZV CZV
B A E D B D E A
CZV CZVF DDC DDD DDC
C A A B
Edition 06.2016

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
20 - Fuel supply system

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2016 Audi AG, Ingolstadt D3E802E927F

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
1.4 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Exploded view - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Deactivating misfuelling prevention device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Fuel delivery unit/fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Exploded view - fuel delivery unit/fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Removing and installing fuel delivery unit/fuel gauge senders . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Checking fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Checking fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Disconnecting plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Exploded view - fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1 Exploded view - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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42
with respect5.3 Removing
to the correctness and installing
of information water
in this document. level
Copyright sender
by AUDI AG. G120 .............................. 42
6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Exploded view - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Removing and installing accelerator pedal module with accelerator position sender G79 /
G185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Contents i
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

ii Contents
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

00 – Technical data
1 Safety precautions
(ARL004739; Edition 06.2016)
⇒ “1.1 Safety precautions when working on the fuel system”, page
1
⇒ “1.2 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “1.4 Safety precautions when working on the SCR system”,
page 4

1.1 Safety precautions when working on the

fuel system
When working on the fuel system note the following warnings:

WARNING

Risk of injury - fuel system operates under pressure.

♦ Wrap a cloth around Protected
the connection beforeforopening
by copyright. Copying the purposes, in part or in whole, is not
private or commercial
fuel system. Then release pressure by carefully loosening
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

the connection.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Wear protective gloves.

♦ Wear safety goggles.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Health risk: avoid skin contact with fuel.
♦ Avoid skin contact with fuel. Wear fuel-resistant gloves.
Escaping fuel can cause a risk.
♦ The power supply for the fuel system pressurisation pump
- G6- must be disconnected before opening the fuel sys‐
tem, since -G6- will be activated briefly when the driver's
door is opened with the battery still connected.
♦ Disconnect power supply by removing fuse for fuel pump
control unit - J538- /fuel delivery unit ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations, or
disconnect battery.

Perform the following steps before starting work on the fuel sys‐
tem:
♦ Fuel tank must not be full. The amount of fuel which can be
left in the fuel tank is indicated in the corresponding procedure
description. Drain fuel tank if necessary ⇒ page 9 .

1. Safety precautions 1
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

♦ Before commencing work, switch on exhaust extraction sys‐

tem and place an extraction hose close to the opening in the
fuel tank to extract escaping petrol fumes.
♦ If no exhaust extraction system is available, a radial fan with
a displacement of at least 15 m3/h can be used (the fan motor
must be clear of the air stream).

WARNING

Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when installing and removing to
reduce weight. Drain fuel tank if necessary ⇒ page 9 .

Observe the following points to prevent personal injuries and

damage to the injection and glow plug system:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as
injectors and gas-discharge headlights.
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
♦ When installing, note colour coding of plug-in connectors.
♦ Plug-in connectors should engage audibly when connecting.
♦ Pull plug-in connectors to check that they are correctly engag‐
ed.
♦ Erase any entries in event memory resulting from testing or
installation ⇒ Vehicle diagnostic tester, Guided Functions ,
then Interrogate
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Caution

To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .

2 Rep. gr.00 - Technical data

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

1.2 Safety precautions when working on ve‐

hicles with start/stop system
When performing repairs on vehicles with start/stop system, note
the following:

WARNING

Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).

1.3 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:

WARNING

Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.

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with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Safety precautions 3
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

1.4 Safety precautions when working on the

SCR system
When working on the SCR system, note the following warnings:

WARNING

Reducing agent can cause skin irritation.

♦ Avoid contact with the skin and eyes. Wear protective
gloves.
♦ If your skin has come into contact with reducing agent,
rinse it off with soap and water.
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♦ If reducing agent gets
permitted intoauthorised
unless your eyes,
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AG. AUDIthem
AG doesoutnotwith
guarantee or accept any liability
water for several
withminutes.
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Do not breathe in or swallow reducing agent.

♦ If you have swallowed reducing agent, rinse your mouth,
drink lots of water and consult a paramedic or doctor im‐
mediately.

Automatic drawing back of reducing agent

• After the ignition is switched off, the reducing agent is auto‐
matically drawn back into the reducing agent tank from the
metering line leading to the injector for reducing agent - N474- .
• Before performing work in this area, you must therefore wait
until the reducing agent has been drawn back; this can take
up to 10 minutes after the ignition has been switched off.
• It is also important to wait until the reducing agent has been
drawn back (i.e. 10 minutes after the ignition is switched off)
before disconnecting the battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .

WARNING

Safety risk due to escaping reducing agent.

♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, wait until the reduc‐
ing agent has been drawn back automatically ⇒ page 4 .

4 Rep. gr.00 - Technical data

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

2 Repair instructions
⇒ “2.1 Rules for cleanliness”, page 5
⇒ “2.2 Test conditions”, page 5
⇒ “2.3 Contact corrosion”, page 5
⇒ “2.4 Routing and attachment of pipes, hoses and wiring”, page
6
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2.1 Rules for cleanliness
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Even small amounts of dirt can cause malfunctions. When work‐
ing on the fuel supply system and injection system, pay careful
attention to the following basic rules:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in their packing (e.g. in tool boxes
etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
♦ Make sure that no diesel fuel comes into contact with other
components in the engine compartment. If necessary, clean
immediately.

2.2 Test conditions

• Battery in standby mode ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
• Fuses for fuel pump/ fuel pump relay - J17- / fuel pump control
unit - J538- OK ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
• Fuel pump relay - J17- OK; checking in Guided Fault Find-
ing ⇒ Vehicle diagnostic tester.

• Fuel pump control unit - J538- OK; checking in Guided Fault

Finding ⇒ Vehicle diagnostic tester.

• Fuel tank at least 1/4 full.

• Fuel filter OK.
• Fuel lines OK (not obstructed or crushed).
• Ignition off.

2.3 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).

2. Repair instructions 5
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
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warranty. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2.4 Routing and attachment of pipes, hoses
and wiring

Caution

Risk of damage to pipes/hoses/wiring.

♦ The original routing must be restored when installing any
kind of pipes/hoses/wiring.
♦ Due to the restricted space in the engine compartment, it
is important to ensure sufficient clearance from all moving
or hot components.

6 Rep. gr.00 - Technical data

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

20 – Fuel supply system

1 Fuel tank
⇒ “1.1 Exploded view - fuel tank”, page 7
⇒ “1.2 Draining fuel tank”, page 9
⇒ “1.3 Removing and installing fuel tank”, page 10
⇒ “1.4 Deactivating misfuelling prevention device”, page 15

1.1 Exploded view - fuel tank

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with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Bolt
❑ 20 Nm
2 - Securing strap
❑ Mounting components
⇒ page 9
3 - Buffer
❑ Mounting components
⇒ page 9
4 - Spacer sleeve
❑ Mounting components
⇒ page 9
5 - Fuel supply line
❑ To fuel filter
❑ Do not kink
❑ Clipped onto fuel tank
❑ Disconnecting and con‐
necting plug-in connec‐
tors ⇒ page 33
6 - Fuel return line
❑ From engine/fuel cooler
❑ Do not kink
❑ Clipped onto fuel tank
❑ Disconnecting and con‐
necting plug-in connec‐
tors ⇒ page 33
7 - Protective plate
❑ For fuel filler neck
❑ Installed according to
vehicle version
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 2 Nm
10 - Overflow hose
11 - Tank flap unit
12 - Filler cap
❑ Screw down until it clicks audibly
❑ Secured to tank flap unit

1. Fuel tank 7
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

13 - Bolt
❑ To secure fuel filler neck
❑ To eliminate electrostatic charge ⇒ page 9
❑ 20 Nm
14 - Earth connection
❑ To eliminate electrostatic charge
❑ Note installation position and refer to notes ⇒ page 9
15 - Fuel tank
❑ Removing and installing ⇒ page 10
❑ Vehicles with SCR system: with filler neck for reducing agent ⇒ page 8
❑ Note SVM code (refer to ⇒ Electronic parts catalogue )
16 - Heat shield
❑ For fuel tank
17 - Locking washer
❑ For heat shield
❑ 2 Nm
18 - Support bracket
19 - Bolt
❑ 20 Nm
20 - Heat shield
❑ For fuel tank
21 - Locking washer
❑ For heat shield
❑ 2 Nm
22 - Fastener
❑ For securing strap

Filler neck for reducing agent for vehicles with SCR system -
tightening torque
– Tighten bolts -2- for filler neck for reducing agent to 2.5 Nm.

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8 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Earth connection for fuel filler neck

– Route earth connection as shown in illustration.
– Make sure that the following connectors are securely seated:
♦ Connector -2- for earth connection on threaded ring -1- of fuel
filler neck
♦ Connector -6- for earth connection on protective cover for fuel
filler neck.
– Engage contact tab -4- of earth connection in mounting hole
on fuel tank -3- and press in spacer bush -5-.

WARNING

Safety risk due to electrostatic discharge.

♦ After installation, use an ohmmeter to check the electrical
connection between the threaded ring on the fuel filler
neck and a bare metal part on the body.
• Specification: approx. 0 Ω

Mounting components for securing strap

1- Washer (front left inside only)
2- Buffer
3- Securing strap
4- Spacer sleeve
5- Bolt

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with respect to the correctness of information in this document. Copyright by AUDI AG.

1.2 Draining fuel tank

Special tools and workshop equipment required
♦ Fuel extractor - VAS 5190A-

1. Fuel tank 9
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Procedure
– Observe safety precautions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 5 .
– Remove flange for fuel gauge sender 2 - G169-
⇒ page 28 .
– Extract fuel from both fuel tank chambers through opening for
fuel gauge sender 2 using fuel extractor - VAS 5190A- .
– Install flange for fuel gauge sender 2 - G169- ⇒ page 28 .

1.3 Removing and installing fuel tank

Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A-

Removing
– Observe safety precautions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 5 .

WARNING

Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when it is removed.

– Drain fuel tank ⇒ page 9 .

– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Fold insulating mat to one side in vicinity of cover for fuel tank
flange.
– Unscrew bolts -arrows- and remove cover for flange.
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10 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Release retainer catches and unplug electrical connectors

-1- and -2- on flange.

– Open tank flap.

– Clean area around fuel filler neck.
– Remove filler cap -arrow- for fuel filler neck.

Note

Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.

– Remove rear wheel housing liner (right-side) ⇒ General body

repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (rear) .

Vehicles without SCR system:

– Remove bolts -1- and -2- for fuel filler neck.

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1. Fuel tank 11
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Vehicles with SCR system:

– Depending on vehicle version, bolts -2- for filler neck for re‐
ducing agent must be removed.
– Remove bolts -1- and -3- for fuel filler neck.
All vehicles (continued):
– Remove rear section of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencer; Exploded view - silencer .

WARNING

The vehicle can tip over on the lifting platform when the rear
axle is removed.
♦ BEFORE loosening the subframe bolts, take steps to en‐
sure that the vehicle does not tip forwards on the lifting
platform ⇒ Running gear, axles, steering; Rep. gr. 42 ;
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Subframe; Exploded view - subframe . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove subframe together with attached components ⇒

Running gear, axles, steering; Rep. gr. 42 ; Subframe; Ex‐
ploded view - subframe .
– Remove heat shield for exhaust system (centre) ⇒ General
body repairs, exterior; Rep. gr. 66 ; Strips / trim panels / ex‐
tensions; Removing and installing heat shield for floor .

WARNING

The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Risk of injury - fuel system operates under pressure.
♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.

– Vehicles with auxiliary heater: Disconnect fuel line -3- for me‐
tering pump.
– Disconnect fuel lines -1 and 2-. Disconnecting plug-in con‐
nectors ⇒ page 33

12 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Vehicles with auxiliary heater: Unplug electrical connector

-1- at metering pump.

– Position engine and gearbox jack - V.A.G 1383 A- under ve‐

hicle to support tank, as shown in illustration.
– In addition, a 2nd mechanic will be required to support the fuel
tank at the rear by hand.

WARNING

Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when it is removed.

– Remove bolts -1 ... 6-.

– Then lower fuel tank using engine and gearbox jack - V.A.G
1383 A- , simultaneously guiding fuel tank down by hand.

Note

For illustration purposes the fuel tank is shown without engine and
gearbox jack.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Fuel tank 13
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Installing
Installation is carried out in the reverse order; note the following:
– Check earth wire for traces of oxidation at connectors; remove
any oxidation if necessary.
– Check that the following connectors are securely seated:
♦ Connector -2- for earth connection on threaded ring -1- of fuel
filler neck
♦ Connector -6- for earth connection on protective cover for fuel
filler neck.
– Engage contact tab -4- of earth connection in mounting hole
on fuel tank -3- and press in spacer bush -5-.

WARNING

Safety risk due to electrostatic discharge.

♦ After installation, use an ohmmeter to check the electrical
connection between the threaded ring on the fuel filler
neck and a bare metal part on the body.
• Specification: approx. 0 Ω

– Check that fuel lines are clipped onto fuel tank.

– Position fuel tank with securing strap and support bracket on

underbody using engine and gearbox jack - V.A.G 1383 A- .
– When installing fuel tank, make sure that fuel filler neck is cor‐
rectly inserted into opening on body.
– Tighten bolts -1 ... 6- for securing strap and support bracket.
– Install cover for flange ⇒ page 18 .
– Install rear seat bench ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seats; Removing and installing seat bench/indi‐
vidual seats .
– Vehicles with auxiliary heater: Bleed fuel line to metering pump
- V54- (fill line with fuel) ⇒ Auxiliary/supplementary heater;
Rep. gr. 82 ; Fuel supply system .

Note

Note SVM code (refer to ⇒ Electronic parts catalogue ).

Tightening torques
♦ ⇒ “1.1 Exploded view - fuel tank”, page 7
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ ⇒ Fig. ““Filler neck for reducing agent for vehicles with SCR
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

system - tightening torque”“ , page 8

with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Subframe; Ex‐

ploded view - subframe
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Strips / trim
panels / extensions; Exploded view - heat shield
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - si‐
lencers
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (rear)

14 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

1.4 Deactivating misfuelling prevention de‐

vice
Special tools and workshop equipment required
♦ Retainer (2x) ⇒ Electronic parts catalogue
Procedure
– Observe safety precautions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 5 .
– Open tank flap.
– Clean area around fuel filler neck.
– Remove filler cap -arrow- for fuel filler neck.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Use screwdriver -2- to press back bottom release tab -1-

-arrow A-.
– Insert retainer -3- in hole in filler neck -arrow B- and press in
until it engages audibly.

– Use screwdriver -1- to press back top release tab -2-

-arrow A-.
– Insert retainer -3- in hole in filler neck -arrow B- and press in
until it engages audibly.

1. Fuel tank 15
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

2 Fuel delivery unit/fuel gauge senders

⇒ “2.1 Exploded view - fuel delivery unit/fuel gauge senders”,
page 16
⇒ “2.2 Removing and installing fuel delivery unit/fuel gauge send‐
ers”, page 18
⇒ “2.3 Checking fuel gauge sender G ”, page 23
⇒ “2.4 Removing and installing fuel gauge sender G ”,
page 25
⇒ “2.5 Checking fuel gauge sender 2 G169 ”, page 26
⇒ “2.6 Removing and installing fuel gauge sender 2 G169 ”, page
28

2.1 Exploded view - fuel delivery unit/fuel gauge senders

1 - Fuel gauge sender - G-

❑ Checking resistance
values ⇒ page 23
❑ Removing and installing
⇒ page 25
2 - Flange
❑ Removing and installing
⇒ page 18
3 - Seal
❑ Renew
❑ Install dry
4 - Locking ring
❑ Loosen and tighten with
wrench - T10202-
❑ 110 Nm
5 - Electrical connector
❑ For fuel gauge sender -
G- and fuel gauge send‐
er 2 - G169-
6 - Electrical connector
❑ For fuel system pressur‐
isation pump - G6-
7 - Electrical connector
❑ For fuel pump control
unit - J538-
8 - Fuel pump control unit -
J538-
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 51 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Checking in Guided
Fault Finding ⇒ Vehi‐
cle diagnostic tester
9 - Bolt
❑ 1.6 Nm
10 - Fuel line to metering pump for auxiliary heater
❑ Different versions

16 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

❑ Do not kink
❑ Clipped onto fuel tank
❑ Disconnecting and connecting plug-in connectors ⇒ page 33
11 - Fuel return line
❑ From engine
❑ Do not kink
❑ Note direction of arrow (fuel supply or fuel return system) on flange when installing
❑ Clipped onto fuel tank
❑ Disconnecting and connecting plug-in connectors ⇒ page 33
12 - Fuel supply line
❑ To fuel filter
❑ Do not kink
❑ Note direction of arrow (fuel supply or fuel return system) on flange when installing
❑ Clipped onto fuel tank
❑ Disconnecting and connecting plug-in connectors ⇒ page 33
13 - Locking ring
❑ Loosen and tighten with wrench - T10202-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 110 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

14 - Flange
❑ Removing and installing ⇒ page 28
15 - Seal
❑ Renew
❑ Install dry
16 - Bracket
❑ For fuel gauge sender 2 - G169-
17 - Fuel gauge sender 2 - G169-
❑ Checking resistance values ⇒ page 26
❑ Removing and installing ⇒ page 28
18 - Electrical wire
❑ For fuel gauge sender 2 - G169-
❑ Located in fuel tank
❑ To renew electrical wire, cut off both ends with connectors as close as possible to last attachment points.
Route new wire parallel to old wiring (old wire remains in fuel tank)
19 - Mounting
❑ Welded to fuel tank
20 - Fuel delivery unit
❑ With fuel system pressurisation pump - G6-
❑ Checking fuel pump (electrical test) in Guided Fault Finding ⇒ vehicle diagnostic tester
❑ Removing and installing ⇒ page 18
❑ Put at least 5 litres of fuel into tank after installing

2. Fuel delivery unit/fuel gauge senders 17

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Cover for flange on fuel tank - tightening torque

– Tighten bolts -arrows- for cover to 1.5 Nm.

2.2 Removing and installing fuel delivery

unit/fuel gauge senders
Special tools and workshop equipment required
♦ Wrench - T10202-

Removing
– Observe safety precautions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 5 .

WARNING

Danger! Fuel may escape.

♦ The fuel tank must not be more than 1/4 full when remov‐
ing the fuel delivery unit, otherwise a large amount of fuel
will escape.

– Drain fuel tank if necessary ⇒ page 9 .

– Move front right seat all the way forwards.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Fold insulating mat to one side in vicinity of cover for fuel tank
flange.
– Unscrew bolts -arrows- and remove cover for flange.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

18 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Release retainer catches and unplug electrical connectors

-1- and -2- on flange.

WARNING

The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Wear protective gloves. with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Wear safety goggles.

Risk of injury - fuel system operates under pressure.
♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.

– Disconnect fuel lines -2 and 3-. Disconnecting plug-in con‐

nectors ⇒ page 33
– Vehicles with auxiliary heater: Disconnect fuel line -1- for me‐
tering pump. Disconnecting plug-in connectors ⇒ page 33

WARNING

Danger! Fuel may escape.

♦ The fuel tank must not be more than 1/4 full when remov‐
ing the fuel delivery unit, otherwise a large amount of fuel
will escape.

– Remove locking ring using wrench - T10202- .

2. Fuel delivery unit/fuel gauge senders 19

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Pull flange slightly out of opening in fuel tank and detach seal.
– Release retainer catch and unplug electrical connector -2-.
– Carefully pull flange -1- with fuel lines out of opening in fuel
tank.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

Safety risk from escaping fuel: the fuel delivery unit is still filled.
♦ Use a cloth to catch escaping fuel.

– Carefully pull fuel delivery unit -2- with fuel gauge sender -1-
out through opening in fuel tank.

Note

When removing fuel delivery unit, make sure you do not bend float
arm of fuel gauge sender -G- .

Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Renew seal.
♦ Ensure that fuel hoses are securely seated.
♦ Take care not to bend float arm of fuel gauge sender -G- when
fitting fuel delivery unit.

20 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Route earth wire as shown in illustration.

1- Earth wire to flange
2- Flange
3- Fuel pressure regulator
4- Earth wire to fuel pressure regulator

Make sure fuel hoses are properly routed:

– Connect fuel supply hose -1- to fuel delivery unit -7-.
– Insert fuel supply hose -4- into guide on fuel delivery unit -7-.
– Fit guide tubes -2- and -6- with spring of flange -3- in guides
on fuel delivery unit.
– Vehicles with auxiliary heater: Make sure that suction pipe
-5- leading to metering pump is correctly inserted in guide on
fuel delivery unit.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Guide electrical wiring for fuel gauge sender 2 - G169- out of

fuel tank.
– Carefully insert fuel delivery unit with fuel gauge sender - G-
in fuel tank.
– Make sure electrical wiring for fuel gauge sender 2 - G169- is
properly routed:
• Guide electrical wiring -4- for fuel gauge sender 2 - G169-
through next to guide tubes -2- and -3- and over fuel supply
hose -1-.
• Guide electrical wiring -4- past electrical wiring -5- for fuel
gauge sender - G- and -6- for fuel system pressurisation pump
- G6- .

2. Fuel delivery unit/fuel gauge senders 21

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Plug in electrical connector -2- for fuel gauge sender 2 - G169-

at flange -1- and make sure it is correctly engaged.

Check:
• Guide tubes -2- and -3- of flange must be inserted in guides
on fuel delivery unit.
• Vehicles with auxiliary heater: Suction pipe -1- leading to me‐
tering pump for auxiliary heater must be inserted in guide on
fuel delivery unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

22 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Install new seal -4- for flange (seal must be installed dry).

Caution

Leakage risk
♦ The seal must not be pinched or damaged when installing
the flange.

– Fit flange in correct installation position.

• Lug -1- on flange must point towards hole -arrow- on locking
ring and must be between tabs -2 and 3- on fuel tank.
– Connect fuel lines so they engage audibly.
– Plug in electrical connectors and make sure they are securely
engaged.
– Install cover for flange ⇒ page 18 .
– Install rear seat bench ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seats; Removing and installing seat bench/indi‐
vidual seats .
– Put at least 5 litres of fuel into tank after installing fuel delivery
unit.
– Vehicles with auxiliary heater: Let auxiliary heater run with full
load for 10 minutes to bleed fuel line leading to metering pump.
Tightening torques
♦ ⇒ “2.1 Exploded view - fuel delivery unit/fuel gauge senders”,
page 16

2.3 Checking fuel gauge sender - G-

Special tools and workshop equipment required
♦ Hand-held multimeter - V.A.G 1526 E-

♦ Auxiliary measuring set - V.A.G 1594C-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Fuel delivery unit/fuel gauge senders 23

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Procedure
– Move front right seat all the way forwards.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Fold insulating mat to one side in vicinity of cover for fuel tank
flange.
– Unscrew bolts -arrows- and remove cover for flange.

– Release retainer catch and unplug electrical connector -2- on

flange.

Note

Disregard -item 1-.

Fuel gauge sender - G- installed:

Note

To obtain an exact measurement of the resistance value for the

specification “Tank full”, the fuel tank must be completely full. For
this, drive for at least 500 metres after filling the tank to let air
bubbles escape from the fuel tank; then add fuel again.

– Connect multimeter (resistance test) as shown in table.

Measure at contacts Tank empty Tank full
2+4 254 … 276 Ω 53 … 71 Ω
2+6 86 … 64 Ω 287 … 269 Ω
4 + 6 1) approx. 340 Ω approx. 340 Ω
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1) Sender in any
withposition
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

24 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Fuel gauge sender - G- removed:

Note

♦ To test the maximum and minimum resistance values for “tank

full” and “tank empty”, remove the fuel delivery unit and move
the sender float all the way to its top or bottom position.
♦ The following values are obtained with the fuel delivery unit
removed, due to the greater travel of the float arm:

– Connect multimeter (resistance test) as shown in table.

Measure at contacts Tank empty Tank full
1+3 max. 53.4 Ω at least 272.7 Ω
2+3 at least 272.7 Ω max. 53.4 Ω
1 + 2 1) approx. 340 Ω approx. 340 Ω
1) Sender in any position
Fuel gauge sender - G- is defective in the following cases:
♦ Large differences in test readings
♦ Reading: 0 Ω (short circuit)
♦ Reading ∞ Ω (open circuit)
♦ No fault in electrical wiring
– Removing and installing fuel delivery unit/fuel gauge senders
⇒ page 18

2.4 Removing and installing fuel gauge

sender - G-
Removing
– Observe safety precautions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 5 .
– Remove fuel delivery unit ⇒ page 18 .
– Pull fuel gauge sender - G- inwards slightly and then lift out
-arrows-.

– If necessary, release retaining tabs -arrows- using a screw‐

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

driver.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Release retainer catch and unplug electrical connector on

flange.
Installing
Installation is carried out in the reverse order; note the following:
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press downwards until it clicks into place.
– Plug in electrical connector and make sure it is correctly en‐
gaged.
– Install fuel delivery unit ⇒ page 18 .

2. Fuel delivery unit/fuel gauge senders 25

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

2.5 Checking fuel gauge sender 2 - G169-

Special tools and workshop equipment required
♦ Hand-held multimeter - V.A.G 1526 E-

♦ Auxiliary measuring set - V.A.G 1594C-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Procedure
– Move front left seat all the way forwards.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Fold insulating mat to one side in vicinity of cover for fuel tank
flange.
– Unscrew bolts -arrows- and remove cover for flange.

26 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Release retainer catch and unplug electrical connector -2- on

flange.

Note

Disregard -item 1-.

Caution

Risk of incorrect measurements.

♦ When measuring the resistance values when the tank is
“empty”, the results may be incorrect because there could
be some fuel left in the side chamber of the fuel tank. To
attain the measured values specified below the remaining
fuel must be drawn out of the tank after opening the flange
⇒ page 28 .

With fuel gauge sender 2 - G169- installed:

Note

To obtain an exact measurement of the resistance value for the

specification “Tank full”, the fuel tank must be completely full. For
this, drive for at least 500 metres after filling the tank to let air
bubbles escape from the fuel tank; then add fuel again.

– Connect multimeter (resistance test) as shown in table.

Measure at contacts 65 ltr. tank: 75 ltr. tank:

Tank empty Tank full Tank empty Tank full
1+3 249 … 286 Ω 51 … 146 Ω 249 … 286 Ω 51 … 90 Ω
1+5 54 … 91 Ω 289 … 194 Ω 54 … 91 Ω 289 … 250 Ω
3 + 5 1) approx. 340 Ω approx. 340 Ω approx. 340 Ω approx. 340 Ω
1) Sender in any position

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Fuel delivery unit/fuel gauge senders 27

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

With fuel gauge sender 2 - G169- removed:

Note

♦ To test the maximum and minimum resistance values for “tank

full” and “tank empty”, remove the fuel gauge sender and move
the sender float all the way to its top or bottom position.
♦ The following values are obtained with the fuel gauge sender
removed, due to the greater travel of the float arm:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Connect multimeter (resistance test) as shown in table.
Measure at contacts Tank empty Tank full
1+3 max. 55 Ω at least 281.8 Ω
2+3 at least 281.8 Ω max. 55 Ω
1 + 2 1) approx. 340 Ω approx. 340 Ω
1) Sender in any position
Fuel gauge sender 2 - G169- is defective in the following cases:
♦ Large differences in test readings
♦ Reading: 0 Ω (short circuit)
♦ Reading ∞ Ω (open circuit)
♦ No fault in electrical wiring
– Install fuel gauge sender 2 - G169- ⇒ page 28 .

2.6 Removing and installing fuel gauge

sender 2 - G169-
Special tools and workshop equipment required
♦ Removal wedge - 3409-

♦ Electric cutter - V.A.G 1561A-

28 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

♦ Blade (L-shaped, 25.4 mm) - V.A.G 1561/22-

♦ Wrench - T10202-

♦ Adhesive sealant ⇒ Electronic parts catalogue

Removing
– Observe safety precautions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 5 .
– Remove luggage compartment floor ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trim panels; Re‐
moving and installing luggage compartment floor .
A7 Sportback:
– Remove front section of rear shelf ⇒ General body repairs,
interior; Rep. gr. 70 ; Passenger compartment trim panels;
Removing and installing rear shelf .
Vehicles with folding rear seat backrest:
– Fold down rear seat backrests.
A6 saloon, A7 Sportback:
– Unclip cover -1- with removal wedge - 3409- -arrow- and de‐
tach.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Fuel delivery unit/fuel gauge senders 29

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

A6 Avant:
– Unclip cover -1- for flange at retainers -arrows- using removal
wedge - 3409- and detach.

All vehicles (continued):

– Use electric cutter - V.A.G 1561A- and blade (L-shaped, 25.4
mm) - V.A.G 1561/22- to cut through adhesive sealant around
cover for flange.
– Detach cover for flange.
– Repair painted surfaces ⇒ Paintwork manual .
– Apply anti-corrosion coating as necessary ⇒ Surface treat‐
ment/chemical materials .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove locking ring using wrench - T10202- .

– Pull flange out of opening in fuel tank.
– Take seal out of opening in fuel tank.

30 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Reach into opening in fuel tank and release fuel gauge send‐
er 2 - G169- by pressing catches -arrows-.
– Pull fuel gauge sender 2 - G169- -item 1- upwards off mounting
and carefully take it out of opening in fuel tank.

Note

When removing, make sure you do not bend float arm of fuel
gauge sender.

Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Renew seal.
♦ When inserting, make sure you do not bend float arm of fuel
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

gauge sender.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Carefully insert fuel gauge sender 2 - G169- in fuel tank.

– Insert fuel gauge sender 2 - G169- into mounting and press
down until it clicks into place.

2. Fuel delivery unit/fuel gauge senders 31

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Install new seal -4- for flange (seal must be installed dry).

Caution

Leakage risk
♦ The seal must not be pinched or damaged when installing
the flange.

– Fit flange in correct installation position.

• Lug -1- on flange must point towards hole -arrow- on locking
ring and must be between tabs -2 and 3- on fuel tank.
– Just before re-installing cover for flange, trim down remaining
adhesive sealing material on cover for flange and on body with
carpet knife to give a smooth surface; do NOT remove sealant
completely.

Note

The remaining material serves as a bonding surface when apply‐

ing the new adhesive sealing material.

Caution

Apply adhesive thoroughly to ensure safe bonding.

♦ Keep bonding surface
Protected clean
by copyright. andforfree
Copying from
private grease.
or commercial purposes, in part or in whole, is not

♦ Do not trim bonding

with respectsurface until shortly before installa‐Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information in this document.
tion.
♦ Do not prime bonding surface and do not treat with clean‐
ing fluid.
♦ Application of primer is only required when fitting a new
cover for flange.

– Cut off tip of nozzle of adhesive sealant cartridge as shown in

illustration.
• Dimension -a- = 7 mm
– Apply new sealant bead onto trimmed-down adhesive sealant
on cover for flange and fit cover.
• Two holes on cover face towards rear of vehicle.
– Install luggage compartment floor ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trim panels; Re‐
moving and installing luggage compartment floor .
– Install front section of rear shelf ⇒ General body repairs, in‐
terior; Rep. gr. 70 ; Passenger compartment trim panels;
Removing and installing rear shelf .
Tightening torques
♦ ⇒ “2.1 Exploded view - fuel delivery unit/fuel gauge senders”,
page 16

32 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

3 Plug-in connectors
⇒ “3.1 Disconnecting plug-in connectors”, page 33

3.1 Disconnecting plug-in connectors

Allocation of plug-in connectors

Note

The plug-in connectors for the fuel lines, vacuum lines, and
breather lines are colour coded. There is either a coloured mark‐
ing on the plug-in connector, or the release tab is the correspond‐
ing colour ⇒ page 33 .

Colour coding
Plug-in connector Colour coding on plug-in connector
Fuel supply Black
Fuel return line Blue
Breather White-beige
Vacuum Green

WARNING

Fuel line is pressurised.

Risk of injury to eyes and skin caused by fuel.
Wear safety goggles and protective
Protected byclothing to avoid
copyright. Copying possible
for private or commercial purposes, in part or in whole, is not
injury and skin contact. Beforepermitted
opening hose connections wrap
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

a cloth around the connection. Then relieve pressure by care‐

with respect to the correctness of information in this document. Copyright by AUDI AG.

fully opening the connection.

Version 1
♦ Plug-in connector with release tabs -arrows- on both sides

3. Plug-in connectors 33
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Disconnecting
– Press plug-in connector -1- in direction of -arrow A-.
– Press in and hold release tabs.
– Unplug plug-in connector -1- from fuel line -2- in direction of
-arrow B-.
• When installing observe colour coding ⇒ page 33 .
• Plug-in connectors should engage audibly when connecting.
– Check that plug-in connector is securely seated by pulling at
it.

Version 2
♦ Plug-in connector with pull release -arrow-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Disconnecting
– Press plug-in connector -1- in direction of -arrow A-.
– Pull the pull release catch -2- in direction of -arrow B-.
– Unplug plug-in connector -1- from fuel line -3- in direction of
-arrow B-.
• When installing observe colour coding ⇒ page 33 .
• Plug-in connectors should engage audibly when connecting.
– Check that plug-in connector is securely seated by pulling at
it.

34 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Version 3
♦ Plug-in connector with release tab at front -arrow-
Disconnecting
– Press release tab -arrow- and disconnect plug-in connectors.
• When installing observe colour coding ⇒ page 33 .
• Plug-in connectors should engage audibly when connecting.
– Check that plug-in connector is securely seated by pulling at
it.

Version 4
♦ Plug-in connector with release tab -arrows- on both sides
Disconnecting
– Press plug-in connector in direction of -arrow A-.
– Press release tabs -arrows- and disconnect plug-in connector.
• When installing observe colour coding ⇒ page 33 .
• Plug-in connectors should engage audibly when connecting.
– Check that plug-in connector is securely seated by pulling at
it.

Version 5
♦ Plug-in connector with release tabs -arrows- on both sides
Disconnecting
– Press release tabs -arrows- and disconnect plug-in connector.
• When installing observe colour coding ⇒ page 33 .
• Plug-in connectors should engage audibly when connecting.
– Check that plug-in connector is securely seated by pulling at
it.

Version 6
♦ Plug-in connector with release tabs -arrows- on both sides
Disconnecting Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Press and hold plug-in connector -1- in direction of -arrow -.

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Press release tabs -arrows- and disconnect plug-in connector.

• When installing observe colour coding ⇒ page 33 .
• Plug-in connectors should engage audibly when connecting.
– Check that plug-in connector is securely seated by pulling at
it.

3. Plug-in connectors 35
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Version 7
♦ Plug-in connector -1- with release tabs -2- on both sides
Disconnecting
– Press and hold plug-in connector -1- in direction of -arrow A-.
– Press release tabs -2- in direction of -arrow B- and unplug
plug-in connector -1-.
• When installing observe colour coding ⇒ page 33 .
• Plug-in connectors should engage audibly when connecting.
– Check that plug-in connector is securely seated by pulling at
it.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

36 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

4 Fuel cooler
⇒ “4.1 Exploded view - fuel cooler”, page 37
⇒ “4.2 Removing and installing fuel cooler”, page 37

4.1 Exploded view - fuel cooler

Note

The fuel cooler is located on the underbody (right-side).

1 - Bolt
❑ 3x Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 1.5 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

2 - Fuel cooler
❑ Removing and installing
⇒ page 37
3 - Spring-type clip
4 - Fuel return line
❑ From engine
5 - Fuel line to metering pump
for auxiliary heater
❑ Different versions
❑ Clipped onto fuel cooler
6 - Fuel supply line
❑ To fuel filter
❑ Clipped onto fuel cooler
7 - Fuel return line
❑ To fuel tank
❑ Clipped onto fuel tank
❑ Disconnecting and con‐
necting plug-in connec‐
tors ⇒ page 33

4.2 Removing and installing fuel cooler

Note

The fuel cooler is located on the underbody (right-side).

Special tools and workshop equipment required

4. Fuel cooler 37
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

♦ Hose clip pliers - VAS 6362-

♦ Drip tray
♦ Protective gloves
♦ Safety goggles
Removing
– Observe rules for cleanliness ⇒ page 5 .
– Remove underbody trim (right-side) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Removing and instal‐
ling underbody trim .

WARNING

The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Risk of injury - fuel system operates under pressure.
♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

38 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Place drip tray under fuel cooler.

– Detach fuel return line -7- from front of fuel cooler.
– Detach fuel return line -3- from rear of fuel cooler. Disconnect‐
ing plug-in connectors ⇒ page 33
– Remove bolts -2, 4 and 6-.
– Unclip fuel lines -1 and 5- from fuel cooler -arrows- and detach
fuel cooler.
Installing
Installation is carried out in the reverse order; note the following:

Note

Secure all hose connections with the correct version of spring-

type clips (same as original equipment) ⇒ Electronic parts cata‐
logue .

Tightening torques
♦ ⇒ “4.1 Exploded view - fuel cooler”, page 37
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Fuel cooler 39
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

5 Fuel filter
⇒ “5.1 Exploded view - fuel filter”, page 40
⇒ “5.2 Removing and installing fuel filter”, page 42
⇒ “5.3 Removing and installing water level sender G120 ”,
page 42

5.1 Exploded view - fuel filter

⇒ “5.1.1 Exploded view - fuel filter (vehicles with horizontal fuel
filter)”, page 40
⇒ “5.1.2 Exploded view - fuel filter (vehicles with vertical fuel fil‐
ter)”, page 41

5.1.1
permitted unlessExploded
authorised by AUDIview - AG
fuel
does filter (vehicles
or accept any with
liability horizontal fuel filter)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
AG. AUDI not guarantee
with respect to the correctness of information in this document. Copyright by AUDI AG.

1 - Bracket
❑ For fuel filter
2 - Nut
❑ 2.1 Nm
3 - Spring-type clip
4 - Fuel supply line
❑ From fuel tank
❑ Clipped onto underbody
5 - Fuel supply line
❑ To engine
❑ Clipped onto underbody
6 - Spring-type clip
7 - Fuel hose
8 - Spring-type clip
9 - Rubber mounting
❑ For fuel filter
10 - Fuel filter
❑ Flow direction is marked
by arrows
❑ Do not interchange con‐
nections
❑ Removing and installing
⇒ page 42
❑ Fitting location: on un‐
derbody (right-side as
seen in direction of trav‐
el)
11 - Spring-type clip
12 - Fuel hose
13 - Rubber grommet
❑ Inserted in body

40 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

5.1.2 Exploded view - fuel filter (vehicles with vertical fuel filter)

1 - Fuel supply line

❑ To engine
❑ Clipped onto underbody
2 - Fuel return line
❑ From engine
❑ Clipped onto underbody
3 - Seal
4 - Filter element
❑ Fitting location: on un‐
derbody (left-side as
seen in direction of trav‐
el)
❑ Removing and installing
⇒ Maintenance ; Book‐
let 411 ; Maintenance;
Fuel filter: renewing
5 - Bolt
❑ Protected
10 Nmby copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
6 - Waterwith
level sender
respect - G120-
to the correctness of information in this document. Copyright by AUDI AG.

❑ Removing and installing

⇒ page 42
7 - Seal
8 - Bolt
❑ 9 Nm
9 - Fuel filter housing
10 - Nut
❑ 5 Nm
11 - Bolt
❑ 20 Nm
12 - Electrical wiring harness
❑ For water level sender - G120-
❑ For heating element
13 - Spring-type clip
❑ Renew
14 - Fuel supply line
❑ To engine
15 - Fuel supply line
❑ From fuel tank
❑ Clipped onto underbody
16 -
17 - Bracket
❑ For fuel filter
18 - Bolt
❑ 9 Nm

5. Fuel filter 41
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

19 - Spring-type clip
❑ Renew

5.2 Removing and installing fuel filter

⇒ “5.2.1 Removing and installing fuel filter - vehicles with hori‐
zontal fuel filter”, page 42
⇒ “5.2.2 Removing and installing fuel filter - vehicles with vertical
fuel filter”, page 42

5.2.1 Removing and installing fuel filter - ve‐

hicles with horizontal fuel filter
Removing and installing fuel filter ⇒ Maintenance ; Booklet 411 ;
Maintenance; Fuel filter: renewing

5.2.2 Removing and installing fuel filter - ve‐

hicles with vertical fuel filter
Removing and installing fuel filter ⇒ Maintenance ; Booklet 411 ;
Maintenance; Fuel filter: renewing

5.3 Removing and installing water level

sender - G120-
Removing
– Observe safety precautions ⇒ page 1 .
–Protected
Observe rules
by copyright. for cleanliness
Copying ⇒ page
for private or commercial 5 . in part or in whole, is not
purposes,
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– with
Remove
respect to underbody
the correctness oftrim (left-side)
information ⇒ General
in this document. body
Copyright repairs,
by AUDI AG.
exterior; Rep. gr. 66 ; Underbody trim; Removing and instal‐
ling underbody trim .
– Remove filter element ⇒ Maintenance ; Booklet 411 ; Main‐
tenance; Fuel filter: renewing .
– Remove nut -1- and take water level sender - G120- out of
filter housing.
Installing
Installation is carried out in the reverse order; note the following:
– Fill/bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling
and bleeding fuel system .
Tightening torques
⇒ “5.1.2 Exploded view - fuel filter (vehicles with vertical fuel fil‐
ter)”, page 41

42 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

6 Accelerator mechanism
⇒ “6.1 Exploded view - accelerator pedal module”, page 43
⇒ “6.2 Removing and installing accelerator pedal module with ac‐
celerator position sender G79 / G185 ”, page 44

6.1 Exploded view - accelerator pedal module

1 - Accelerator pedal module

❑ With accelerator posi‐
tion sender - G79- and
accelerator position
sender 2 - G185-
❑ Checking in Guided
Fault Finding ⇒ Vehi‐
cle diagnostic tester
❑ Depending on engine/
gearbox type, adaption
may need to be per‐
formed in “Guided Func‐
tions” mode after renew‐
al. If this menu item is
available in “Guided
Functions”, perform
adaption ⇒ Vehicle di‐
agnostic tester.
❑ Removing and installing
⇒ page 44 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - Pedal bracket with respect to the correctness of information in this document. Copyright by AUDI AG.

3 - Bolt
❑ 8 Nm
4 - Electrical connector

6. Accelerator mechanism 43
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

6.2 Removing and installing accelerator

pedal module with accelerator position
sender -G79- / -G185-
Removing
– Remove dash panel cover (bottom, driver side) ⇒ General
body repairs, interior; Rep. gr. 68 ; Shelves / trim panels; Re‐
moving and installing dash panel cover (driver side) .
– Push release tab -1- upwards -arrow- and unplug electrical
connector -2-.
– Remove bolt -3- and take out accelerator pedal module down‐
wards.

Installing
Installation is carried out in the reverse order; note the following:
– Attach accelerator pedal module -4- to bottom of pedal bracket
-1-, insert centring pin -2- and tighten bolt -3-.
– Install dash panel cover (bottom, driver side) ⇒ General body
repairs, interior; Rep. gr. 68 ; Shelves / trim panels; Removing
and installing dash panel cover (driver side) .
– Depending on engine/gearbox type, adaption may need to be
performed in “Guided Functions” mode after renewal. If this
menu item is available in “Guided Functions”, perform adap‐
tion ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ “6.1 Exploded view - accelerator pedal module”, page 43

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

44 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

7 Fuel pump
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
page 45
⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page
51

7.1 Checking fuel system pressurisation

pump - G6-
Special tools and workshop equipment required
♦ Pressure tester (diesel) - VAS 6551-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Adapter set - VAS 6551/5-

♦ Pressure control valve - VAS 6551/6-

♦ Vehicle diagnostic tester

♦ Fuel-resistant measuring container

7. Fuel pump 45
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

A - Checking fuel delivery rate

Note

The test procedure for the 3.0 ltr. TDI engine is shown as an ex‐
ample.

– Observe test conditions ⇒ page 5 .

– Open tank flap.
– Remove filler cap -arrow- for fuel filler neck.

WARNING

The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Risk of injury - fuel system operates under high pressure.
♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.

– Release hose clip -2- and detach fuel supply hose -3- leading
to high-pressure pump from fuel supply line -1-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Note
with respect to the correctness of information in this document. Copyright by AUDI AG.

If the connection point is not accessible, the air cleaner housing

must be removed in order to carry out the following work steps ⇒
Rep. gr. 23 ; Air cleaner; Removing and installing air cleaner
housing .

– Connect pressure tester (diesel) - VAS 6551- to fuel supply

line with connecting line - VAS 6551/5-2- and secure with hose
clip.
– Attach pressure control valve - VAS 6551/6- and hold end of
hose into fuel-resistant measuring container.

46 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Switch on pressure tester (diesel) - VAS 6551- -item 1- by

pressing On/Off button.

Note

To measure the fuel delivery rate, pressure must first be built up

in the fuel supply line; the fuel pump must then operate against
this pressure during the measurement. This pressure can be built
up using the pressure control valve - VAS 6551/6- as follows:

– Open cut-off valves -A and B-.

• Levers must point in direction of flow.

Caution

Risk of fuel escaping.

♦ Cut-off valve -C- must be closed.
♦ The lever should point perpendicular to direction of flow.

– Connect vehicle diagnostic tester .

– Switch on the ignition and select the following menu options
on the vehicle diagnostic tester:
♦ Vehicle self-diagnosis
♦ Engine electronics
♦ Basic setting
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Checking fuel system pressurisation
permitted unless authorised
pump by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Press Start : The fuel pump will start running.

7. Fuel pump 47
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Build up pressure in fuel system by turning adjuster screw

-1- on pressure control valve - VAS 6551/6- until correct pres‐
sure is reached.
• Specification: 4 bar
– From this point on, do not turn adjuster screw -1-.
– Press Stop .
– Drain measuring container.
– For measurement, press Start again and let fuel pump run
for 15 seconds.
– Press Stop after 15 seconds.
– Check amount of fuel delivered in measuring container.
• Specification: minimum delivery rate 750 cm3/15 sec.
If the minimum delivery rate is attained:
♦ Fuel supply line with fuel filter and fuel pump are OK
♦ However, there may be a fault in the return line. For Fault
Finding, perform “Pressure test for entire system”
⇒ page 50 .
If minimum delivery rate is not achieved, check for the following
causes:
♦ Fuel pump or fuel pressure regulator in fuel tank faulty.
♦ Blocked fuel filter or crushed fuel line.

Note

To find the precise cause of the fault, a pressure test must be

performed on the fuel supply line as described below.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

48 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

B - Pressure test on fuel supply line

• Leave measuring equipment connected in the same way as
for measuring the fuel delivery rate.
• Vehicle diagnostic tester still connected.
– Switch on pressure tester (diesel) - VAS 6551- -item 1- by
pressing On/Off button.
– Open cut-off valve -A-.
• Lever must point in direction of flow.

Caution

Risk of fuel escaping.

♦ Cut-off valves -B and C- must be closed.
♦ The levers should point perpendicular to direction of flow.

– Press Start on vehicle diagnostic tester display to start the

fuel pump.
– Press Stop after 15 seconds.
– Read fuel pressure off pressure tester (diesel) - VAS 6551- .
• Specification: at least 6.0 bar
If specification is attained although fuel delivery rate was not OK:
♦ Blocked fuel filter or crushed fuel supply line.
If specification is not attained:
♦ Fuel pump or fuel pressure regulator in fuel tank faulty.

Note

♦ To detect any faults in the fuel return line or in the relief valve
of the high-pressure pump, a pressure test must be performed
on the entire system as described below.
♦ Before disconnecting the measuring equipment, release the
fuel pressure by opening the cut-off valves -B and C- and al‐
lowing fuel to drain off into a measuring container.

– Detach pressure control valve - VAS 6551/6- and remove to‐

gether with measuring container.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Fuel pump 49
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

C - Pressure test for entire system

• Fuel delivery rate and pressure test on fuel supply line OK
• Connecting line - VAS 6551/5-2- connected to fuel supply line
and to pressure tester (diesel) - VAS 6551- .
• Vehicle diagnostic tester connected.
– Attach connection fitting - VAS 6551/5-1- to fuel supply hose
-1- leading to high-pressure pump, secure with hose clip and
attach connecting line - VAS 6551/2- .
– Attach connecting line - VAS 6551/2- to pressure tester (die‐
sel) - VAS 6551- .

Note

In this way the pressure tester (diesel) - VAS 6551- is connected

into the fuel supply line.

– Switch on pressure tester (diesel) - VAS 6551- -item 1- by

pressing On/Off button.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Open cut-off valves -A and permitted
B-. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Levers must point in direction of flow.

Caution

Risk of fuel escaping.

♦ Cut-off valve -C- must be closed.
♦ The lever should point perpendicular to direction of flow.

– Switch on the ignition and select the following menu options

on the vehicle diagnostic tester :
♦ Vehicle self-diagnosis
♦ Engine electronics
♦ Basic setting
♦ Checking fuel system pressurisation pump
– Press Start : The fuel pump will start running.
– Read fuel pressure off pressure tester (diesel) - VAS 6551- .
• Specification: 3.8 ... 5.8 bar
If the indicated value is below the specification, although the fuel
delivery rate was OK:
♦ Relief valve in high-pressure pump not OK
If the indicated value is higher than the specification (more than
6 bar):
♦ Fuel return line blocked or crushed.
Assembling
Installation is carried out in the reverse order; note the following:
• The ignition must be switched off.

50 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Note

Before removing the pressure tester -1-, release the fuel pressure
by opening the cut-off valves -B, C- and allowing fuel to drain off
into a measuring container.

– Detach pressure tester (diesel) - VAS 6551- together with

connecting lines.
– Secure fuel supply line with hose clip and then pull to check
that fuel supply line is properly secured.

7.2 Removing and installing fuel pump con‐

trol unit
Protected by copyright. - for
Copying J538-
private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Observe safety precautions ⇒ page 1 .

– Observe rules for cleanliness ⇒ page 5 .

Caution

To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.

– Disconnect earth wire from battery terminal ⇒ Electrical sys‐

tem; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .

WARNING

Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when lowering it.

– Drain fuel tank ⇒ page 9 .

– Remove rear wheel housing liner (right-side) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (rear) .
Vehicles without SCR system:
– Remove bolts -1- and -2- for fuel filler neck.

7. Fuel pump 51
 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

Vehicles with SCR system:

– Depending on vehicle version, bolts -2- for filler neck for re‐
ducing agent must be removed.
– Remove bolts -1- and -3- for fuel filler neck.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

All vehicles (continued):

WARNING

Risk of accident caused by weight of fuel tank

♦ Fuel tank must be empty when lowering it.

– Remove bolts -1 ... 6-.

Note

♦ The fuel tank is lowered onto the subframe.

♦ The fuel tank is shown without the subframe for illustration
purposes.

– Remove rear seat bench ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
– Fold insulating mat to one side in vicinity of cover for fuel tank
flange.
– Unscrew bolts -arrows- and remove cover for flange.

– Remove bolts -1- and -2-.

– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and underbody -arrow-.

52 Rep. gr.20 - Fuel supply system

 Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Fuel supply system, diesel engines - Edition 06.2016

– Unplug electrical connector -arrow- and detach fuel pump con‐

trol unit - J538- .
Installing
Installation is carried out in the reverse order; note the following:
– Install cover for flange ⇒ page 18 .
– Install rear seat bench ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seats; Removing and installing seat bench/indi‐
vidual seats .
– Connect battery and perform steps required after re-connect‐
ing battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
Tightening torques
♦ ⇒ “2.1 Exploded view - fuel delivery unit/fuel gauge senders”,
page 16
♦ ⇒ “1.1 Exploded view - fuel tank”, page 7
♦ ⇒ Fig. ““Filler neck for reducing agent for vehicles with SCR
system - tightening torque”“ , page 8
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (rear)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Fuel pump 53