Audi Workshop Service and Repair Manuals

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

t  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.

Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Slide cover above battery to the right -arrow 1- and lift off -arrow 2-.

–  With ignition switched off, disconnect earth strap -arrow- at battery. –  Briefly open filler cap for fuel tank and close again.

–  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 The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection.

–  Disconnect fuel line -1- from flange (right side of vehicle) by pressing release tab. –  On vehicles with auxiliary heater, also disconnect fuel line -2- leading to metering pump for auxiliary heater (press release tab).

WARNING 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.   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 The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection.

–  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 at Y-connector.

–  Reach into fuel tank opening on right side of vehicle and pull fuel supply pipe -4- out of baffle housing. –  Press connecting piece -1- to the right and unclip it from baffle housing. –  Disconnect supply pipe -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 supply pipe -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 line to Y-connector -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 with fuel gauge sender 2 -G169- into 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-.

–  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. –  Connect battery. Observe notes on procedures required after connecting battery → Rep. Gr.27. Tightening torque

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