Question 1

What precautions should be observed before working on the Fuel Level Sensor and Fuel Pump for Petrol engines on Audi 100?

Accepted Answer

Before working on fuel system components, observe the necessary precautions. The fuel pump and gauge sender unit are combined in one assembly, mounted on the top of the fuel tank, with access via a hatch in the load space floor. Removal of the unit exposes the tank contents to the atmosphere, so extreme care must be taken to prevent fire, ensuring the area inside and around the car is well ventilated to avoid fuel fume build-up. Begin by depressurising the fuel system, then park the vehicle on a level surface and disconnect the battery negative lead. Remove the trim from the load space floor, slacken and remove the access hatch screws, and lift the hatch away from the floorpan. Unplug the wiring connector from the pump/sender unit, place rags beneath the fuel and vent hoses to catch any spilt fuel, and disconnect the fuel return and vent hoses, identifying each hose for position. Unscrew and remove the union bolt securing the feed hose to the pump/sender unit, recovering the sealing washers, and plug or tape over the ends of the hoses to prevent dust and dirt from entering the fuel system. Unscrew the plastic securing ring and carefully lift out the pump/sender unit, taking care not to damage the wiring; a special tool is typically used for this, but two screwdrivers or water pump pliers may also work. Disconnect the supply and return hoses from inside the unit, then disconnect the wiring from the fuel pump. Turn the pump unit anticlockwise approximately 15 mm to release it from its bayonet fitting, lifting it out while holding it above the fuel level until excess fuel drains out, and recover the rubber seal. Inspect the float at the end of the sender unit swinging arm for punctures and fuel ingress, renewing it if damaged, and check the rubber seal from the fuel tank aperture, renewing it if necessary. Clean any dirt and debris from the sender unit wiper and track, looking for breaks in the track. To refit, reverse the removal procedure, inserting the fuel pump so that the V-mark aligns with the first mark, then turning it clockwise until the V-mark aligns with the second mark, and smear the tank aperture rubber seal with clean fuel before fitting it in position.

Question 2

How to replace the high-pressure fuel pump on Audi A4?

Accepted Answer

In the case of 2.0L four-cylinder engines, start by depressing the fuel system pressure and unplugging the cable of the negative battery terminal. The second step would entail disconnection of the electrical connectors of the low fuel pressure sensor and the fuel pressure regulator valve and then disconnection of both fuel lines on the high-pressure pump making sure that the fitting is held with a wrench when it is loosened. Put off the three mounting fasteners of the high-pressure pump, noting that the Schrader valve fitting may have to be removed to access the bolt, then remove the pump, remembering that the sleeve may still be attached to the cylinder head. Dispose the old pump O-ring and always install a new one. Installation Before fitting the pump, place the sleeve into the cylinder head and turn the crankshaft until the sleeve seats at the lowest point and press it firmly into place as you turn the engine. After attaching the sleeve, attach the pump using a new O-ring, screw-in the mounting fasteners in a diagonal pattern and firmly attach the Schrader valve should it be fitted. Reconnect and secure the fuel lines then reconnect the electrical lead to the low fuel pressure sensor and fuel pressure regulator valve. In the case of 3.2L V6, one should begin by emptying out the engine coolant, and then drain away the front coolant pipe, as well as the upper intake manifold. Ease the high-pressure fuel line fittings, remove the fuel line bracket fasteners, and unscrew the fuel line fittings. In case equipped, disconnect electrical connector with the high-pressure pump and remove the large lifting eye. The pump and actuator should be carefully pulled off without bending or kinking the fuel lines. Reject the old O-ring of the pump and install only the new O-ring. Once more, lift the fuel lines in order to fit the high-pressure pump with a new O-ring and do not rip the lines. Install and screw the pump mounting fasteners, hand tighten the threaded fittings of the fuel lines and do not strain any but securely install the fuel line bracket fasteners and tighten the fuel line fittings. Installation is complete and this is done by following the reverse steps of removal and filling the cooling system.

Genuine Audi Fuel Pump

138 Fuel Pumps found

Audi Suction Pipe Part Number: 4B0-201-865-A

Audi Fuel Pump Assembly Part Number: 1K0-919-050-AB

Audi Fuel Pump Assembly Part Number: 5Q0-919-050-BA

Audi Suction Line Part Number: 3D0-919-715-H

Audi Suction Line Part Number: 3D0-919-715-J

Audi Fuel Pump Assembly Part Number: 5QF-919-087-S

Audi Fuel Pump Assembly Part Number: 5Q0-919-087-T

Audi Fuel Pump Part Number: 4M0-919-087-BP

Audi Fuel Pump Part Number: 4M0-919-087-F

Audi Fuel Pump Assembly Part Number: 5N0-919-109-F

Audi Fuel Pump Assembly Part Number: 4K0-919-087-P

Audi Fuel Pump Assembly Part Number: 4N0-919-088-A

Audi Fuel Pump Assembly Part Number: 4K0-919-087-AB

Audi Fuel Pump Assembly Part Number: 80A-919-087

Audi Fuel Pump Assembly Part Number: 80A-919-087-F

Audi Fuel Pump Assembly Part Number: 4K0-919-087-Q

Audi Fuel Pump Part Number: 4N0-919-088-C

Audi Fuel Pump Assembly Part Number: 8E0-919-051-BL

Audi Fuel Pump Part Number: 4E0-919-087-J

Audi Suction Line Part Number: 4E0-919-715

Audi Fuel Pump

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