How to Replace a Fuel Pump on a Audi A4

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The A4 is an entry-level luxury car sold by German automaker Audi. The A4 was first sold in the United States in 1994, and it continues to be a popular and highly rated vehicle. The Audi engineering team designed the fuel system quite a bit differently from most American cars; but with the right tools, mechanical aptitude and patience, you can replace the fuel pump.

Things You'll Need

  • Pliers
  • Labels
  • Socket wrench set
  • Dry rag
  • Torque wrench
  • Audi tool #3307
  • Audi tool #3217
  • Drain pan
  • Make sure your fuel gauge reads one-third full or below before beginning the procedure. Relieve pressure from the fuel system by removing the fuel pump relay in the engine fuse box (it will be labeled).

  • Remove the fuel filler cap and crank the engine. Let the engine idle until the fuel in the lines runs out; the engine will shut off when the line is empty. Turn the ignition off.

  • Disconnect the negative battery cable with the pliers.

  • Open the trunk and remove the carpet and the trunk flooring cover. Locate the fuel tank access directly behind the rear passenger seat in the center. Remove the screw from the cover.

  • Lift the cover and use Audi tool #3217 with the socket wrench to remove the nut. With the nut removed, you will gain access to the fuel pump.

  • Label the fuel pump hoses for input and output; you need to be able to properly connect the lines to the new fuel pump.

  • Use Audi tool #3307 with the socket wrench to remove the fuel pump. Slightly turn the fuel pump counterclockwise to unlock it for removal. Carefully disconnect the lines, with the pump wrapped in a towel, to minimize leakage. Remove the electrical connectors and place the old fuel pump in the drain pan.

  • Use Audi tool #3307 with the socket wrench to insert the new fuel pump. Turn the pump clockwise slightly to lock, and then attach the electrical connectors and the hoses.

  • Reinstall the fuel tank nut cover using Audi tool #3217 with the torque wrench. Tighten the nut to 50 foot-pounds. Replace the trunk floor lining and the carpet, reconnect the negative battery cable and replace the fuel filler cap.

Tips & Warnings

  • Contact your local Audi dealer for Audi tools #3307 and #3217. You can also check with an auto parts store to see if an equivalent aftermarket tool is available.
  • The fuel system is under intense pressure; never work around the fuel pump or lines without first relieving fuel system pressure.

References

  • Photo Credit http://commons.wikimedia.org/wiki/User:Thomas_doerfer
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