Suction jet pump, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Identifying Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wrench T10202

Removing

Observe safety precautions → Safety precautions when working on fuel supply system .

Observe rules for cleanliness → 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. Procedure → Fuel tank, draining .
Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

All except Audi RS4:

Fig 2: Pushing Cover Over Battery Toward Right And Removing It Upward

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Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 3: Locating Battery Ground Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Audi RS4:

Raise luggage compartment floor covering and secure.

Fig 4: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

All:

Open fuel filler flap briefly and then close again.
Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 5: Removing Cover Bolts For Locking Flange

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Unbolt cover for right locking flange - arrows -.

Audi RS4:

Fig 6: Removing Electrical Wires With Connector From Locking Flange Opening

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Free up electrical connector - arrow - for Fuel Pump (FP) Control Module J538 and disconnect.

All:

Fig 7: Disconnecting Electrical Harness Connector At Right Locking Flange

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Disconnect electrical harness connector - arrow - at right locking flange.

Fig 8: Identifying Fuel Return Line And Fuel Supply Line

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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.

Fig 9: Removing/Installing Locking Ring With Wrench T10202

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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.

Fig 10: Identifying Suction Jet Pipe & Fuel Delivery Line

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Disconnect suction jet pipe - 1 - to suction jet pump by pressing release button.
Disengage fuel delivery line - 2 -.

Fig 11: Removing Cover Bolts For Locking Flange

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Unbolt cover for left locking flange - arrows -.

Fig 12: Disconnecting Electrical Harness Connector At Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at left locking flange.

Fig 13: Removing/Installing Locking Ring With Wrench T10202

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Remove locking ring on left using wrench T10202.
Pull locking flange and sealing ring from opening of fuel tank.

Fig 14: Carefully Pull Locking Flange With Fuel Level Sensor 2 G169 With Suction Jet Pump Partially Out Of Fuel Tank Opening

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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.

Fig 15: Identifying Suction Jet Pipe & Fuel Delivery Line

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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:

Fig 16: Identifying Fuel Supply Line, Guide Tube & Supports For Fuel Return Line

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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.

Fig 17: Identifying Tab On Locking Flange Lie Between Tabs On Fuel Tank

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Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Fig 18: Removing/Installing Locking Ring With Wrench T10202

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Tighten right locking ring.

Fig 19: Identifying Fuel Return Line And Fuel Supply Line

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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.

Fig 20: Identifying Tab On Locking Flange Must Lie Between Tabs On Fuel Tank

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Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

NOTE:

- Arrow - points in direction of travel.

Fig 21: Removing/Installing Locking Ring With Wrench T10202

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Tighten left locking ring.
Connect battery. Observe safety precautions after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

Torque specifications

Component	Nm
Lock ring for fuel delivery unit and locking flange of Fuel Level Sensor 2 G169	145