100 V6 Fuel Pump Replacement BTDTs?

[Craig D. Niederst]

Chris,
I found that you may need the special Audi fuel pump removal tool #3214
(available from Zelenda Tools for ~$30). This tool rotates the plastic pump
holder in the tank so it could be pulled out. I spent two evenings
attempting to remove mine without the tool, and I had no luck at all. From
what I read in the archives, its probably a 50/50 shot you can get it out
without the tool. Also, make sure you have 1/4 tank of gas or less (siphon
some out if you have too), or you will have your arm in fuel for a good bit
of time. The actual Bosch replacement fuel pump is ~$100 from The Parts Bin,
etc. My 1st replacement one was defective, and was noisy from the initial
engagement of the pump. It was a Czech Republic made unit, which other
listers have mentioned appear to be lower quality than OEM. The metal pump
housing is actually a bit shorter than the OEM, which means it does not seat
as snugly as it should. This leaves a little gap around the plastic part,
which allows dirty fuel to be pulled into the pump (it bypasses the screens
that remove the larger particulates which ruin the pumps). I returned the
Bosch one and got a German made VDO one (~$130 but has a longer metal
housing), and it has been quiet and troublefree so far (~ 1 month). Also
make sure you get some copper crush washers to replace the ones on the banjo
fitting on the top of the sending unit (part # N0138128). HTH.

Craig
'92 100S (99k)
'86 CGT (216k)

----- Original Message -----
From: "RYAN ALAN HOITINK" <rahoitink at students.wisc.edu>
To: <cflanner at hotmail.com>
Cc: <quattro at audifans.com>
Sent: Sunday, September 08, 2002 7:29 PM
Subject: RE: 100 V6 Fuel Pump Replacement BTDTs?


> Chris-
>
> You don't need any special Audi tools.  All you need to get the top
> ring off is a hammer and a flathead screwdriver.  Just pound around
> the ring in a CCW direction.  BTDT several times.  After that,
> disconnect the fuel lines (banjo bolts) and wiring at the top of the
> fuel level sensor(should be obvious).  Then pull the assembly out of
> the tank to get at the fuel pump.  Be prepared to have your arm
> immersed in fuel for a while after this.  I found that the easiest way
> to get the pump out is to just push out on the three tabs holding it
> in place while trying to pull up on it.  This is quite a tedious job,
> as only one arm will fit in the hole, and when you have your arm in,
> you lose all vision.  Once you have done the job once, it becomes much
> easier.
>
> Good luck.
>
> -Ryan
>
>
>
> -----------------------------
>
> My dad's '93 100 V6 needs a new fuel pump.  Any BTDTs?  I have a big
> stack of Bentleys but I don't have one for this car.  I'm assuming
> I'll need the fuel pump tool 3214.  Please advise.  TIA!
>
> Chris
>
>
>
>
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