my fuel pump just gave up the ghost on way home from xmas vacation.

[Luxus Panzer]

Fuel pump died on the highway.

The pump started to make noises when we left my grandmas to come home (5h drive) and gave out about 150 KM later.

No CEL, but vag com had a fault under the engine for fuel trim lean or something like that. I can get it to start, but it sputters out even when gas pedal held down.

SOOOOO...

I got towed to my Father in laws and will open it up tomorrow. No parts stores open until Monday.

I have found the DIY on A4 MODS and I am wondering if if anyone has any other links to fuel pump DIYs or any other things I need to look out for while I am in there.

Basically if anyone has any input on this fuel pump swap, please share as I have all day tomorrow to prepare for the job.

[Matt Devo]

the DIY on A4mods is all you need, it's pretty easy as long as you don't have a > 1/2 full tank

[Lornnn]

Sorry to hear that man... what a pain. I recently changed mine out with the help of that A4Mods DIY and its all pretty straightforward.

Cleanliness is probably most important here. The locking ring on mine was caked with all kinds of shit so you'll probably want to spend a good amount of time making sure any surfaces near the opening are as clean as you can get them. Quite a bit of debris was knocked loose while using the tools I had. The last thing you want is to go through all of this and possibly burn out a brand new pump because some trash got knocked in there. As the DIY states you should have your tank as close to empty as possible so you can also clean the cage out with paper towels or a rag.

One thing that I had trouble with was getting the old pump to unlock from the plastic cage. The DIY says "It only takes a little effort to move the fuel pump" but I really had to work the thing out with the hammer+flathead technique (I didn't have the VAG tool) because the pump wouldn't budge without causing the entire cage to rattle to the point where I thought I might damage something. It eventually came loose, though... hopefully its easier for you. Locking the new one in shouldn't be much of an issue at all.

Overall its a very easy job while following the DIY. Might also be a good idea to change out your fuel filter as well.

Good luck, no sweat.

[Let it snow]

I made a cheap tool to remove the pump from the basket. If you can find 1/2" O.D. copper pipe or something similar. Two 1 foot pieces or longer for better torque. Hammer the ends down about 1". Bend flat part about a 45 degree angle. When you get to the pump removal from the basket sit flat parts in notches on opposite sides and twist. I made it because i did not like the hammer method. Good luck.

[A4OrlandoB6]

awesome ^ are the two pieces fused/welded together or does it just look like that?

[Let it snow]

awesome ^ are the two pieces fused/welded together or does it just look like that?

Nope not welded or secured at the middle. A good idea though. When i twisted the torque kept them together. Some tape wrapped around the crossing section would be an easy cheap way to go. I just grabbed some scrap pipe hoping it would be one time use. Good luck Luxus.

[Luxus Panzer]

thanks all.

Super pain in the ass.

I can not order parts today (Sunday) so I will get everything clean and apart today. I will also empty my gas tank as I am JUST over 1/2 full.

I will keep everyone posted. Yes, I got my 1st b6 on a flatbed pic...will post as soon as I get it off my wife's phone.


Now, as to brands I see this VDO unit. Is VDO OEM??
http://www.autopartsway.ca/partdetai.../pagenum1/tabs

[Luxus Panzer]

while I wait.

Where is my fuel pump relay and is there a reliable way to test it?

[ADCS]

If I had to guess I would guess Bosch for the OEM pump but looking at all the parts websites VDO seems correct.

Dead fuel pump really sucks though...happened to me several years ago. This would be a great time to replace your fuel filter as well. You can pick up a MANN filter from AutoPartsWay.

[Let it snow]

while I wait.

Where is my fuel pump relay and is there a reliable way to test it?

Remove electrical connector from fuel pump. Terminal 1 and 4 is pump supply voltage. turn key but don not start you should have battery voltage for a few seconds. Try to start the car you should have constant battery voltage. If you have both relay should be okay.

[Luxus Panzer]

If I had to guess I would guess Bosch for the OEM pump but looking at all the parts websites VDO seems correct.

Dead fuel pump really sucks though...happened to me several years ago. This would be a great time to replace your fuel filter as well. You can pick up a MANN filter from AutoPartsWay.

Fuel filter was the first thing I did when I bought the car :)

[Luxus Panzer]

Remove electrical connector from fuel pump. Terminal 1 and 4 is pump supply voltage. turn key but don not start you should have battery voltage for a few seconds. Try to start the car you should have constant battery voltage. If you have both relay should be okay.

Thanks man!

I am away from home and my Bently....where exactly is the fuel pump relay is case I have to diagnose it ?


And here it is....my first B6 on a flatbead pic :(

[Matt Devo]

Now, as to brands I see this VDO unit. Is VDO OEM??
http://www.autopartsway.ca/partdetai.../pagenum1/tabs

yes

[Luxus Panzer]

well pump is out while I await a new one.

The pump did not prime with key and would spit a bit of fuel out when key held to start (had a clear pipe to a gas can hooked up to the pump)

How many PSI are supposed to be coming out of the fuel pump?? I do not think I had more than 20-30 PSI when I got the pump running (guesstimate)

[john_gonzo]

Fuel filter was the first thing I did when I bought the car :)

A failing fuel pump can produce fragments, etc. that end up in the filter. Not a bad idea to put a new one on after you get the new pump installed.

Also, 4B0886373 01C is the part number for the rear seat retainer. This clip can break during seat removal when gaining access to the fuel pump. Same part number should be available at VW dealer. Info from this thread: Part-Number-Rear-Seat-Hold-Down-Retainer.

[old guy]

How many PSI are supposed to be coming out of the fuel pump?? I do not think I had more than 20-30 PSI when I got the pump running (guesstimate)

The fuel filter regulates the fuel pressure to 4-bar (58 psi).

[Luxus Panzer]

The fuel filter regulates the fuel pressure to 4-bar (58 psi).

Thanks!

So what PSI does the pump produce before the fuel filter ?

[old guy]

Thanks!

So what PSI does the pump produce before the fuel filter ?

Good question! All I can say for sure is that it is more than 4-bar. I'll check the Bentley and see if it lists anything for the pump itself.

[Luxus Panzer]

Good question! All I can say for sure is that it is more than 4-bar. I'll check the Bentley and see if it lists anything for the pump itself.

Wish I could but I am stranded away from home and away from my Bentley.

[Luxus Panzer]

Drove to Newmarket today and picked up a pump Pfaff had in stock. Going to return the one I ordered whenever it gets here.

Put the new pump in...she fires right up :)

She lives!!!
Thanks all.

[john_gonzo]

Drove to Newmarket today and picked up a pump Pfaff had in stock. Going to return the one I ordered whenever it gets here.

Put the new pump in...she fires right up :)

She lives!!!
Thanks all.

Congrats! That's a fine looking beast.

[SlickFix]

Isn't that a fun job in the cold and snow? I had to do the same thing last winter.

[Luxus Panzer]

Isn't that a fun job in the cold and snow? I had to do the same thing last winter.

Painful