Suction Jet Pump, Removing and Installing
Suction Jet Pump, Removing And Installing
Special tools, testers and auxiliary items required
- Wrench T10202
Removing
Observe safety precautions.
Observe rules for cleanliness.
CAUTION:
- To remove the suction jet pump, the fuel tank may only be filled to a maximum of 1 / 4. Drain fuel tank if necessary.
- Observe procedures for disconnecting battery.
All except Audi RS4:
- Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 - .
- With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
Audi RS4:
- Raise luggage compartment floor covering and secure.
- With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
All:
- Open fuel filler flap briefly and then close again.
- Remove rear seat bench.
- Unbolt cover for right locking flange - arrows - .
Audi RS4:
- Free up electrical connector - arrow - for Fuel Pump (FP) Control Module J538 and disconnect.
All:
- Disconnect electrical harness connector - arrow - at right locking flange.
- Mark fuel return line - 1 - and fuel supply line - 2 - .
CAUTION: The fuel system is under pressure. Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.
- Pull both lines from locking flange, by pressing release buttons.
CAUTION: Locking flange may only be opened when fuel tank is maximum 1 / 4 full. Otherwise, a large amount of fuel will spill out.
- Remove locking ring using wrench T10202 .
- Remove locking flange and seal from opening in fuel tank and lay aside locking flange with lines still connected.
- Disconnect suction jet pipe - 1 - to suction jet pump by pressing release button.
- Disengage fuel delivery line - 2 - .
- Unbolt cover for left locking flange - arrows -.
- Disconnect electrical harness connector - arrow - at left locking flange.
- Remove locking ring on left using wrench T10202.
- Pull locking flange and sealing ring from opening of fuel tank.
- Carefully pull the locking flange - 1 - with fuel level sensor 2 G169 with suction jet pump - 2 - toward left and out of fuel tank opening.
NOTE: When removing, be sure not to bend floater arm of fuel level sensor 2 G169.
Installing
Installation is in reverse order of removal. Note the following:
NOTE:
- Replace seal.
- When installing, be sure not to bend floater arm of fuel level sensor 2 G169 .
- Push suction jet pump with lines at left side of vehicle into fuel tank opening.
- Reach into fuel tank opening on right side of vehicle and pull suction jet pump with lines into installed position.
- Attach fuel delivery line - 2 - .
- Push suction jet pipe - 1 - onto suction jet pump until it engages audibly.
Make sure fuel hoses are routed correctly:
- The fuel supply line - 1 - must be routed between guide tube - 4 - and supports - 2 - for fuel return line. Also, it must be routed around outside of guide tube - 3 -.
- Insert guide tubes - 3 - and - 4 - of locking flange into guide holes - arrows - of fuel delivery unit.
NOTE: To improve clarity, the fuel delivery unit is shown without the fuel tank.
- Install new locking flange seal dry.
- Press locking flange down against spring pressure and bring it into installation position.
- Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.
- Tighten right locking ring.
- Install fuel supply line - 2 - and fuel return line - 1 - according to the marking.
- Connect electrical harness connector.
- Install new locking flange seal dry.
- Press locking flange down against spring pressure and bring it into installation position.
- Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.
NOTE: - Arrow - points in direction of travel.
- Tighten left locking ring.
- Connect battery. Observe safety precautions after connecting battery.
Torque specifications
Lock ring for fuel delivery unit and locking
flange of Fuel Level Sensor 2 G169 145 Nm