Suction jet pump in left fuel tank chamber, removing and installing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wrench T10202

Fig 2: Fuel Pump Wrench 3307

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel pump wrench 3307

Removing

NOTE:

The following describes removal of suction jet pump for left half of fuel tank. The suction jet pump for the right side of the fuel tank is a component of the baffle housing and cannot be replaced separately.

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 for the left fuel tank chamber, the fuel tank may only be filled to a maximum of ¹ /₄ full. 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
.

Fig 3: Pushing Cover Over Battery Toward Right And Removing It Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 4: Locating Battery Ground Strap

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

Fig 6: Identifying Right Locking Flange Electrical Harness Connectors

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Disconnect electrical harness connector - 1 - at right locking flange.
Disengage electrical harness connector - 2 - and lay it aside.

CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Fig 7: Identifying Fuel Line & Ventilation Line

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Disconnect fuel line - 1 - from right locking flange by pressing release button.
Disconnect ventilation line - 2 - 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 8: Removing/Installing Locking Ring With Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove locking ring using wrench T10202.

Fig 9: Separating Electrical Connection On Inner Side Of Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull locking flange and sealing ring from opening of fuel tank.
Disconnect electrical connection on inner side of locking flange - arrow -.

NOTE:

To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

Fig 10: Guiding Fuel Pump Wrench 3307 Through Fuel Tank Opening And Placing It On Fuel Delivery Unit

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
Release fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward left until stop (bayonet connection).

Fig 11: Identifying Notch Aligns With Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Notch - 1 - aligns with marking - 2 -.

Remove fuel delivery unit.

NOTE:

Be aware that fuel is still in the fuel delivery unit.

Fig 12: Removing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt cover for left locking flange - arrows -.

Fig 13: Disconnecting Electrical Harness Connector At Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Fig 14: Pulling Fuel Line Off From Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull fuel line - arrow - off from left locking flange, by pressing release button.

Fig 15: Removing/Installing Locking Ring With Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left locking ring using wrench T10202.

Fig 16: Identifying Fuel Line, Locking Flange, Fuel Level Sensor 2 G169 & Suction Jet Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully pull locking flange with Fuel Level Sensor 2 G169 and seal slightly out of fuel tank opening.
Remove fuel line - 1 - from fuel tank.
Pivot locking flange - 2 - with fuel level sensor 2 G169 - 3 - and suction jet pump - 4 - out of fuel tank opening.

NOTE:

When removing, be sure not to bend floater arm of fuel level sensor 2 G169.

Unclip suction jet pump from locking flange with Fuel Level Sensor 2 G169.

Fig 17: Press Release Buttons And Separate Fuel Hose At Y-Fitting

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Press release buttons - arrows - and separate fuel hose at the Y-fitting.

Fig 18: Identifying Suction Jet Line, Distribution Piece, Fuel Return Line & Fuel Line

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Reach into fuel tank opening on right side of vehicle and pull suction jet line - 4 - out of baffle housing.
Push distribution piece - 1 - toward right and unclip it from baffle housing.
Disconnect fuel return line - 3 - at distribution piece - 1 -.

NOTE:

The fuel line - 2 - remains connected.

Reach into fuel tank opening on left side of vehicle and pull suction jet pump with lines out toward left.

Installing

Installation is in reverse order of removal. Note the following:

NOTE:

Replace seals.
Make sure fuel hoses are seated securely.

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 19: Identifying Suction Jet Line, Distribution Piece, Fuel Return Line & Fuel Line

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Push fuel return line - 3 - on at distribution piece - 1 - , until hose couplings are engaged.
Clip distribution piece to baffle housing.
Insert fuel delivery line - 4 - into corresponding hole of baffle housing.

Fig 20: Identifying Fuel Line, Locking Flange, Fuel Level Sensor 2 G169 & Suction Jet Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clip suction jet pump - 4 - to locking flange - 2 - of fuel level sensor 2 G169 , and connect fuel line to Y-coupling - 1 -.

NOTE:

When installing, be sure not to bend floater arm of fuel level sensor 2 G169.

Install new locking flange seal dry.
Bring locking flange of Fuel Level Sensor 2 G169 to installation position.

Fig 21: 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 22: Removing/Installing Locking Ring With Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten locking ring.

NOTE:

To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

Fig 23: Identifying Notch Aligns With Marking

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Insert fuel delivery unit into baffle housing in tank so that the notch - 1 - at the fuel delivery unit aligns with marking - 2 - at baffle housing.

Fuel delivery unit can be pressed downward significantly and noticeably.

Fig 24: Guiding Fuel Pump Wrench 3307 Through Fuel Tank Opening And Placing It On Fuel Delivery Unit

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.
Fasten fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15 ° toward right until stop (bayonet connection).

Fig 25: Identifying Notch Aligns With Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Notch - 1 - aligns with marking - 3 -.

Fig 26: Separating Electrical Connection On Inner Side Of Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect electrical connection - arrow - on inner side of locking flange.
Install new locking flange seal dry.
Bring locking flange to installation position.

Fig 27: Identifying Tab On Locking Flange Lies Between Tabs On Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

- Arrow - points in direction of travel.

Fig 28: Removing/Installing Locking Ring With Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten 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
Locking ring for fuel delivery unit or Fuel Level Sensor 2 G169 locking flange		145