Removing and installing suction jet pump with connection piece — AUDI

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Special tools and workshop equipment required

Spanner for fuel tank sender unit 3087
Fuel pump spanner 3307
Release tool T40020

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 replaced separately.

Removing

Observe safety precautions=> Page
20-1
.

Observe rules for cleanliness => Page
20-4
.

The fuel tank must not be more than1/4full when removing the suction jet pump. Drain the fuel tank if necessary. Procedure=>Page
20-119
.

Obtain code on vehicles with coded radio/integrated radio and navigation system.
With ignition switched off disconnect battery earth strap.
Open fuel filler cap briefly, then close it again.
Remove rear seat bench.

=> General body repairs, Interior; Repair group 72; Rear seats; Removing and installing rear seat bench
General body repairs, Interior
Rear seats
Removing and installing rear seat bench

Detach cover for flange on fuel tank under rear seat bench (right side).

Carefully release 4-pin connector -arrow- and unplug.

Warning
Fuel system is under pressure. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
Mark supply pipe -1- and return pipe -2- and disconnect from flange (right side of vehicle).

The fuel tank must not be more than 1/4 full when removing the suction jet pump. Otherwise a large amount of fuel will escape.
Remove locking ring with spanner for fuel tank sender unit 3087.

Remove flange and seal out of opening in fuel tank.
Unplug both connectors -1- and -2- for fuel gauge senders on inside of flange.

Insert fuel pump spanner 3307 through opening in fuel tank and apply spanner to inner section of baffle housing.

Turn inner section of baffle housing together with pump anti-clockwise as far as it will go (approx. 15°).
Notch -1- will then be aligned with marking -2- (bayonet fitting).

Take out fuel pump with inner section of baffle housing.

Press retaining tab, and at the same time pull the sender unit out of baffle housing guide -arrows-.

Note:

The baffle housing is shown without the fuel tank for a clearer illustration.

Unclip connecting piece -1- from lower section of baffle housing. To do this, carefully press connecting piece towards left side of vehicle and lift out -arrow-.

Note:

The connecting piece and surrounding area are shown without fuel tank for a clearer illustration.

To pull return hoses -4- and -5- off connecting piece, ...

... release hose connectors on return pipes with release tool T40020.

Pull hose -2- out of baffle housing.
Unclip rigid pipe -3- from connecting piece.

Remove cover for flange on fuel tank (left) below rear seat.
Carefully release 2-pin connector -arrow- on fuel gauge sender II (left side of vehicle) and unplug.

Unscrew locking ring (left side of vehicle) using spanner for fuel gauge sender unit 3087.
Carefully pull fuel gauge sender II a short distance out of fuel tank opening together with seal.
Unplug connector for fuel gauge sender I on inside of flange for fuel gauge sender II.

Reach into fuel tank and release retainer tabs -arrows- below suction jet pump -2-.
Pull fuel gauge sender II (-1-) off suction jet pump.

Note:

The sender is shown without the fuel tank for a clearer illustration.

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 detached after removal.

Installing

Install in reverse sequence; note the following points:

Note:

Secure all hose connections with the correct hose clips (same as original equipment)

=> Parts catalogue

Push suction jet pump (with hoses and connecting piece fitted) into fuel tank opening on right side of vehicle.
Reach into fuel tank opening on left side of vehicle and pull suction jet pump with hoses and connecting piece into their final position.
Fit rigid pipe -3- into corresponding hole in baffle housing -6-.
Press return hoses -1 and 2- onto connecting piece -4- so that the hose connectors engage.

Notes:

Always use new O-rings -7- for fuel return pipe.
Lubricate O-rings for fuel return pipe with fuel.

Clip rigid pipe -3- into connecting piece -4-; at the same time engage connecting piece in baffle housing -6-.

Insert fuel gauge sender I into guide on outer section of baffle housing and press down until it clicks into place -arrow-.

Insert hose -5- into corresponding hole in baffle housing -6-.

Fit inner section of baffle housing into outer section of baffle housing (in tank) so that notch -1- on inner section of housing is aligned with marking -2- on outer section of housing.
Inner section of baffle housing should move down noticeably.

Insert fuel pump spanner 3307 through opening in fuel tank and apply spanner to inner section of baffle housing.

Turn pump together with inner section of baffle housing clockwise as far as it will go (approx. 15°).
Notch -1- will then be aligned with marking -3- (bayonet fitting).

Connect electrical connectors -1- and -2- for fuel gauge sender on inside of flange.

Fit new sealing ring for flange in fuel tank opening (sealing ring should be dry).
Make sure there is clearance for wires -2- to fuel pump and to return hose -1- when installing flange.

Note:

Note routing of auxiliary supply pipe on vehicles with auxiliary heater.

=> Auxiliary heater; Repair group 82; Fuel supply to auxiliary heater; Fuel supply (to auxiliary heater) from fuel tank
Auxiliary heater
Fuel supply to auxiliary heater
Fuel supply (to auxiliary heater) from fuel tank

When installing flange, turn in direction indicated (arrow in illustration).

Fit flange into fuel tank; note correct installation position:
Marking on flange -1- must coincide with marking on fuel tank -2-.

Note:

Arrow points in direction of travel.

Tighten locking ring (120 Nm).
Fit supply pipe and return pipe as marked.
Fit cover for flange so that the projecting part is above the electrical connector.

Install fuel gauge sender II as follows:

Note:

Do not bend arm of float on fuel gauge sender when installing.

Plug in connectors and insert fuel gauge sender II (-1-) into fuel tank.
Fit suction jet pump -2- inside fuel tank onto fuel gauge sender II. Retaining tabs -arrows- must engage.

Fit new seal for fuel gauge sender II in fuel tank opening (seal should be dry).

Note fitting position of fuel gauge sender II:
Marking on sender -2- must coincide with marking on fuel tank -1-.

Tighten locking ring (120 Nm).
Fit cover for flange so that the projecting part is above the electrical connector.

Notes:

When the battery is reconnected, re-activate electrical equipment (radio/radio and navigation system, clock, electric windows) as described in the Owner's Manual.
Further procedures after reconnecting the voltage supply:

=> Motronic injection and ignition system; Repair group 24
Motronic injection and ignition system

Tightening torques

Component · Nm
Locking ring for fuel delivery unit · 120
Battery terminal to battery post · 5