Audi Workshop Service and Repair Manuals

Removing and installing suction-jet pump in left fuel tank chamber Special tools and workshop equipment required

t  Special wrench -T10202-

t  Fuel pump spanner -3307- Removing   Note This section describes how to remove the suction-jet pump in the left fuel tank chamber. The suction-jet pump in the right fuel tank chamber is part of the baffle housing and cannot be renewed separately. Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 1/4 full when removing the suction-jet pump for the left fuel tank chamber. Drain the tank if necessary. Procedure → Chapter.

–  Remove rear seat bench → Rep. Gr.72. –  Unscrew cover for flange (right-side) -arrows-.

–  Unplug electrical connector -arrow- at flange (right side of vehicle).   WARNING t  The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles.

–  Disconnect fuel line -arrow- from flange (right side of vehicle) by pressing release tab. Vehicles with auxiliary heater: –  In addition, disconnect fuel line leading to metering pump for auxiliary heater by pressing release tab.

All models:   Caution The fuel tank must not be more than 1/4 full when opening the flange. Otherwise a large amount of fuel will escape. –  Unscrew locking ring using wrench -T10202-.

–  Detach flange with seal from fuel tank opening. –  Unplug electrical connector -arrow- on inside of flange.

–  Carefully pull flange (together with fuel hose -2- coming from fuel pump) out of fuel tank until Y-connector is visible. –  Press release tabs -arrows- and disconnect fuel hose at Y-connector. –  Reach into fuel tank opening and disconnect fuel hose -1- from fuel delivery unit.   Note

Fuel tank is shown in a cut-away view for illustration purposes. –  Insert fuel pump spanner -3307- through fuel tank opening and apply at fuel delivery unit.

–  Release fuel delivery unit by turning to stop (approx 15°) in anti-clockwise direction (bayonet connection) using fuel pump spanner -3307-. l  Notch -1- will then be aligned with marking -2-. –  Remove fuel delivery unit.   Note Keep in mind that the fuel delivery unit still contains fuel.

–  Detach cover for flange (left-side) -arrows-.

–  Unplug electrical connector -arrow- at flange (left side of vehicle).   WARNING t  The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles.

–  Disconnect fuel line -arrow- from flange (left side of vehicle) by pressing release tab.

–  Unscrew locking ring using wrench -T10202- (left side of vehicle).

–  Carefully pull flange with fuel gauge sender 2 -G169- and seal just slightly out of opening in fuel tank. –  First pull fuel line -1- out of fuel tank. –  Swivel flange -2- with fuel gauge sender 2 -G169--item 3- and suction-jet pump -4- out of fuel tank opening.   Note When removing, make sure you do not bend float arm of fuel gauge sender 2 -G169-. –  Unclip suction-jet pump from flange with fuel gauge sender 2 -G169-.

–  Press release tabs -arrows- and disconnect fuel hose from connector.

–  Pull fuel supply pipe -4- out of baffle housing. –  Press connecting piece -1- to the right and unclip it from baffle housing. –  Disconnect fuel line -3- from connecting piece -1-.   Note Fuel line -2- remains connected. –  Reach into fuel tank opening on left side of vehicle and pull out suction-jet pump, with pipes pointing towards the left. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals. t  Ensure that fuel hoses are securely seated. –  Push suction-jet pump (with pipes attached) into fuel tank opening on left side of vehicle.

–  Reach into fuel tank opening on right side of vehicle and pull suction-jet pump with pipes into the installation position. –  Push fuel line -3- onto connecting piece -1- so that the hose connectors engage. –  Clip connecting piece onto baffle housing. –  Fit fuel supply pipe -4- into corresponding hole in baffle housing.

–  Clip suction-jet pump -4- onto flange -2- of fuel gauge sender 2 -G169- and fit fuel pipe to connecting piece -1-.   Note When installing, make sure you do not bend float arm of fuel gauge sender 2 -G169-.

–  Install new seal for flange (seal must be installed dry). –  Move flange to installation position. l  Lug -2- on flange must be between tabs -1- and -3- on fuel tank.   Note The -arrow- points in direction of travel.

–  Tighten locking ring.   Note

Fuel tank is shown in a cut-away view for illustration purposes. –  Fit fuel delivery unit into baffle housing (in tank) so that notch -1- on fuel delivery unit is aligned with marking -2- on baffle housing. l  The fuel delivery unit should move down noticeably.

–  Insert fuel pump spanner -3307- through fuel tank opening and apply at fuel delivery unit.

–  Secure fuel delivery unit by turning to stop (approx 15°) in clockwise direction (bayonet connection) using fuel pump spanner -3307-. l  Notch -1- will then be aligned with marking -3-.

–  Reach into fuel tank opening and insert fuel hose -1- into appropriate hole on fuel delivery unit. –  Connect fuel hose -2- to Y-connector.

–  Attach electrical connector -arrow- to inside of flange.

–  Install new seal for flange (seal must be installed dry). –  Move flange to installation position. l  Lug -2- on flange must be between tabs -1- and -3- on fuel tank.   Note The -arrow- points in direction of travel.

–  Tighten locking ring. –  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 supply pipe going to metering pump. Tightening torque

Component	Nm
Locking ring for fuel delivery unit or flange of fuel gauge sender 2 -G169-	145