Audi Workshop Service and Repair Manuals

Removing and installing suction-jet pump Special tools and workshop equipment required

t  Wrench -T10202- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  The fuel tank must not be more than 1/3 full when removing the suction-jet pump. Drain the tank if necessary. Procedure → Chapter.   Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect battery → Rep. gr.27.

–  Remove rear seat bench → Rep. gr.72. –  Unclip the retaining tabs -arrows- for the flange cover (right-side).

–  Unplug electrical connector -arrow- at flange.

–  Mark fuel supply line -1- and fuel return line -2-.   WARNING 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 connection. –  Detach both pipes from flange (press release tabs). Vehicles with auxiliary heater: –  In addition, disconnect fuel supply pipe for auxiliary heater. Procedure → Rep. gr.82.

All vehicles (continued):   Caution The fuel tank must not be more than 1/3 full when removing the fuel delivery unit. Otherwise a large amount of fuel will escape. –  Unscrew locking ring using wrench -T10202-. –  Take flange and seal of fuel delivery unit out of opening in fuel tank and move clear, leaving pipes connected.

–  In opening in fuel tank, press release tab to disconnect supply pipe -2- to suction-jet pump. –  Disconnect fuel supply pipe -1- (press release catch -arrow-).

–  Unclip the retaining tabs -arrows- for the flange cover (left-side).

–  Unplug electrical connector -1- at flange. –  Disengage electrical connector -2- and move it clear to the side.

–  Unscrew locking ring using wrench -T10202-.

–  Carefully pull fuel gauge sender 2 -G169--item 2- together with suction-jet pump -1- just slightly out of opening in fuel tank. –  Detach seal. –  Unclip suction-jet pump from flange -arrows-.   Note When removing, make sure you do not bend float arm of fuel gauge sender 2 -G169-. –  Reach into fuel tank opening on left side of vehicle and pull out suction-jet pump, with pipes pointing towards the left. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following:   Note t  Renew seals. t  When installing, make sure you do not bend float arm of fuel gauge sender 2 -G169-. –  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. –  Fit supply pipe -1-, so that it engages (you should hear it click into place). –  Fit supply pipe -2- leading to suction-jet pump so that it engages audibly. –  Install new seal for flange (seal must be installed dry). –  Slot guide sleeve on flange into guide sleeve on fuel delivery unit; make sure spring is not damaged.

–  Press flange down against spring pressure, and turn flange to installation position. l  Lug -2- on flange points towards arrow marking, and must be between tabs -1- and -3- on fuel tank.   Note The -arrow- points in direction of travel.

–  Tighten locking ring.

–  Carefully insert fuel gauge sender 2 -G169--item 2- into opening in fuel tank. –  Clip suction-jet pump -1- onto flange -2-, so that you hear it click into place (press jaws of retainer apart slightly -arrows- at flange).

–  Install new seal for flange (seal must be installed dry). –  Press flange down against spring pressure, and turn flange to installation position. l  Lug -2- on flange points towards arrow marking, and must be between tabs -1- and -3- on fuel tank.   Note The -arrow- points in direction of travel.

–  Tighten locking ring. –  Install rear seat bench → Rep. gr.72. –  Observe notes on procedures required after connecting battery → Rep. gr.27.