Suction Jet Pump, Removing and Installing (AWD)

Suction Jet Pump With Distributor Connector, Removing And Installing

Special tools, test equipment and auxiliary items







- 3087 Wrench 3307
- Fuel Pump Wrench
- T40020 Unblocking Tool

NOTE: The following describes the removal of the suction jet pump on the left side of the fuel tank. The right suction jet pump is part of the accumulator and cannot be separately replaced.

Removing
- For removing the filler neck with expansion tank, the fuel tank should not be over 1/ 4 full. If necessary, empty fuel tank.

CAUTION: After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar(R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

- Vehicles with coded radio/navigation system (RNS) coding, refer to the Owner's Manual, if necessary.

Audi A6:







- Remove cover above battery -arrow-.


NOTE: On vehicles without separate battery cover: Remove plenum cover.







- Disconnect battery Ground (GND) strap -arrow-, with ignition switched off.

WARNING: When removing suction jet pump the fuel tank should only be 1/4 full. Drain fuel tank if necessary.

Audi RS6:







- Turn locks -arrow- counterclockwise and remove cover -1-
- Remove cover -1- upward







- With ignition switched off, disconnect battery Ground (GND) cable -arrow-.

All:
- Briefly open and close fuel tank cap.
- Remove rear seat bench.







- Remove cover for closing flange under rear seat bench, right-side.







- Carefully disengage 2-pin harness connector -arrow- and disconnect. (4-pin harness connector shown).

WARNING:
- Fire Hazard. Do not smoke, work near heaters or have anything in the area that could ignite the fuel or fumes.
- Fuel supply lines are under pressure. Before loosening any lines, cover the connection with a rag. Release the pressure by slowly separating the connection.







- Mark fuel supply line -1- and fuel return line -2- and disconnect from closing flange (right side).

WARNING: When removing suction jet pump the fuel tank should only be 1/4 full. Otherwise large quantities of fuel escape.







- Unbolt closing ring using 3087 Wrench.
- Remove flange and seal out of opening in fuel tank.







- Disconnect both connectors -1- and -2- for fuel gauge sender on inside of flange.







- Insert fuel pump spanner 3307 through opening in fuel tank and apply spanner to inner section of accumulator.
- Using spanner 3307 turn inner section of accumulator counter-clockwise (approx. 15 degrees)







- Notch -1- should line up with marking -2-.

- Remove fuel pump with inner section of accumulator.
- Pull corrugated hose between accumulator and connecting piece out of accumulator.







- Press retaining tab, and at the same time pull the sender unit out of accumulator in fuel tank -arrows-.


NOTE: For better illustration purpose the accumulator is shown without fuel tank.







- Unclip connecting piece -1- from lower section of accumulator. To do this, carefully press connecting piece toward left side of vehicle and lift out -arrow-.
- Pull return hoses -4 and 5- off connecting piece (release hose connectors).
- Pull hose -2- out of accumulator.
- Unclip rigid pipe -3- from connecting piece.







- In addition, unlock quick coupling line connectors of the return pipes with unlocking tool T40020.







- Remove cover -arrows- for fuel tank sender.
- Remove cover for closing flange below rear seat bench (left side).







- Carefully release 2-pin connector -arrow- on fuel level sensor 2 (left side of vehicle) and disconnect.







- Unscrew locking ring (left side of vehicle) using spanner for fuel gauge sender unit 3087.
- Carefully pull fuel level sensor 2 a short distance out of fuel tank opening together with seal.
- Disconnect harness connector for fuel gauge sender on inside of fuel level sensor 2.







- Reach into fuel tank and release retainer tabs -arrows- below suction jet pump -2-.
- Pull fuel level sensor 2 -1- off suction jet pump.


NOTE: The sensor 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 toward the left.


NOTE: The suction jet pump and connecting piece can be removed after removal.

Installing
Installation is carried out in the reverse order, when doing this note the following:

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

- 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.







- Install rigid pipe -3- into corresponding holes in accumulator -6-.
- Press return hoses -1 and 2- onto connecting piece -4- so that the hose connectors engage.


NOTE:
- Always install new seals -7- for return line.
- Ensure that the seals are not crushed; use a suitable lubricant if necessary.







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







- Insert sender for fuel gauge into guide on outer section of accumulator and press down until it clicks into place.







- Insert hose -5- into corresponding hole in accumulator -6-.







- Install inner section of accumulator into outer section of accumulator (in tank) so that notch -1- on inner section of housing is aligned with marking -2- on outer section of housing.
- It should be possible to press down the inner section of the accumulator noticeably.







- Apply fuel pump spanner 3307 trough opening and place on accumulator.







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







- Disconnect harness connectors for fuel gauge sender on inside of flange.
- Insert new seal for closing flange into opening of fuel tank (seal should be dry).







- When inserting closing flange ensure that wiring -2- to fuel pump and fuel return line -1- is positioned correctly.







- When installing, turn flange in direction of -arrow-, as in illustration.







- Install flange in fuel tank; note correct installation position:
- Marking on flange -1- should be aligned with marking on fuel tank -2-.

NOTE: -Arrow- points in direction of travel.







- Tighten sealing ring (120 Nm).
- Install supply and return hoses (according to identifying marks).
- Install cover for flange so that the projecting part is above the electrical connector.
- Install fuel level sensor 2 as follows:

NOTE: Do not bend sender when installing.







- Connect connectors and insert fuel level sensor 2 -1- into fuel tank.
- Install suction jet pump -2- inside fuel tank onto fuel level sensor. Retaining tabs -arrows- must engage.
- Install new seal for fuel level sensor 2 in fuel tank opening (seal should be dry).







Note correct position of fuel level sensor 2:
- Marking on flange -2- must be aligned with marking on fuel tank -1-.







- Tighten locking ring (120 Nm).
- Install supply and return hoses (according to identifying marks).
- Install cover for flange so that projecting part is above electrical connector.
- After connecting battery, enter anti-theft code for radio.

NOTE: With Battery re-connected, remember to activate electrical equipment (radio, clock, window switches) according to operating instructions.

- Generate readiness code.

Tightening torque

Component Torque Nm
Closing ring for fuel pump delivery module 145 Nm (106 ft lb)
Battery connections 5 Nm (44 in. lb)