Removing and installing suction jet pump with connecting piece — AUDI

🧭 Before you start

Fits: Audi A6 C5 (4B)

• Renewed: connecting piece, seals, o-rings in hose connector

Don't miss

• The baffle housing is shown without fuel tank for illustration purposes.
• The area around the connecting piece is shown without fuel tank for illustration purposes.Unclip pipe (1) from connecting piece to renew connecting piece.
• The sender is shown without fuel tank for illustration purposes.
• The suction jet pump and connecting piece can be disconnected after removal.
• The area around the connecting piece is shown without fuel tank for illustration purposes.

🔧 Engine codes this applies to

📐 60 workshop diagrams for AFB

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove fuel delivery unit .
2. Press retaining tab, and at the same time pull fuel gauge senderG out of baffle housing guide (arrows). [Note: The baffle housing is shown without fuel tank for illustration purposes.]
3. Unclip connecting piece on lower section of baffle housing. To do this, carefully press connecting piece towards left side and lift out.
4. Unclip rigid pipe (2) from connecting piece.
5. Pull return pipe (3) off connecting piece (release hose connector on return pipe). [Note: The area around the connecting piece is shown without fuel tank for illustration purposes.Unclip pipe (1) from connecting piece to renew connecting piece.]

6. Detach cover for flange (left-side) (arrows).
7. Unplug electrical connector (arrow) at flange (left side of vehicle).
8. Unscrew locking ring (left side of vehicle) using special wrench T10202.
9. Carefully pull fuel gauge sender 2G169(item 1) and seal just slightly out of opening in fuel tank.
10. Unplug electrical connector for fuel gauge senderG on inside of flange for fuel gauge sender 2G169.
11. Reach into fuel tank and release retainer tabs (arrows) below suction jet pump (2). [Note: The sender is shown without fuel tank for illustration purposes.]
12. Disconnect fuel gauge sender 2G169 from suction jet pump.
13. Reach into fuel tank opening on left side of vehicle and pull out suction jet pump with hoses and connecting piece towards the left. [Note: The suction jet pump and connecting piece can be disconnected after removal.] [Note: Renew seals.Renew O-rings in hose connector on connecting piece.When installing, make sure you do not bend float arm of fuel gauge sender 2 G169.]
14. Push suction jet pump (with hoses and connecting piece fitted) into fuel tank opening on right side of vehicle.
15. Reach into fuel tank opening on left side of vehicle and pull suction jet pump with hoses and connecting piece into their final position.
16. Fit rigid pipe (2) into corresponding hole in baffle housing.
17. Push fuel return pipe (3) onto connecting piece so that the hose connector engages.
18. Clip rigid pipe (2) into connecting piece while engaging connecting piece in baffle housing [Note: The area around the connecting piece is shown without fuel tank for illustration purposes.]
19. Insert fuel gauge senderG into guide on outer section of baffle housing and press down until it clicks into place (arrow).
20. Install fuel delivery unit .
21. Carefully insert fuel gauge sender 2G169(item 1) with electrical connectors fitted into opening in fuel tank.
22. Fit suction jet pump (2) inside fuel tank onto fuel gauge sender 2G169. Retaining tabs (arrows) must engage.
23. Install new seal for flange (seal must be installed dry).
24. Move flange with fuel gauge sender 2G169 into installation position.
25. Tighten locking ring.
26. Plug in electrical connectors.
27. Install cover for flange so that the projecting part is above the electrical connector.
28. Install rear seat bench 72.

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