In-Tank Fuel Pump Replacement

[Fred Munro]

Marc;

The OEM pump was Bosch. Around 1990 the mounting method for the in-tank
pumps changed. The older cars had the pumps mounted on a three-point
spider - these pumps are easy to remove. The later cars had the pump mounted
in a plastic "bucket" and secured by a plastic locking ring. There is a
special tool to engage and remove the locking ring. Some rings can be turned
by hand, some can't. When I replaced the pump on my '91 200q I couldn't get
the ring off by hand or with any of the improvised tools I came up with, so
I had to button the tank back up and take it to the dealer.
I replaced the pump on my '91 with a Bosch. The replacement pump was made in
Czechoslovakia, the original was made in Germany. The dealer tech looked at
the new pump and said "Hmm, made in Czechoslovakia. My home country. This
one will be noisy." He was right.
If you do this job yourself, drain most of the gas from the tank and use
non-sparking tools. Don't even think about using a trouble light around the
open tank; use a flashlight or something with an unbreakable lens. Make sure
you have plenty of ventilation - the gas fumes get quite potent after you've
been in the trunk for 20 minutes wrestling with the pump.

I have heard the Pierburg pumps are quieter and cheaper but required some
mods to fit. I haven't ever used one, so no BTDT.

Fred Munro
'94 S4


-----Original Message-----
From: quattro-bounces+munrof=sympatico.ca at audifans.com
[mailto:quattro-bounces+munrof=sympatico.ca at audifans.com]On Behalf Of
Marc Boucher
Sent: February 6, 2004 9:40 PM
To: quattro at audifans.com
Subject: In-Tank Fuel Pump Replacement


Went outside to check which pump I've got so I can order a replacement.
Some suppliers have told me that some 100's in 1990 were fitted with 44mm
and others with 60mm pumps and there's no way to know without getting out
the old one.

Our local Bosch dealer looked up the car and said there is only one pump
listed for it...Bosch part number 254040.  Cost: $275 Canadian (equals about
$205 US).

One of the online Audiparts sites mentioned that they stopped carrying Bosch
pumps due to noise issues.  Anyone have any thoughts on Bosch vs. Pierburg
pumps?  I still don't know what type mine is equipped with however the
sender unit cover is labelled VDO which I understand is a third supplier of
fuel pumps used in the 100?

Got as far as getting the sender unit opened up so I can see inside the
tank.  Seems like the pump is firmly mounted to the bottom of the tank.  Any
thoughts on the level of difficulty involved in replacing an in-tank pump?
I'm prepared to do a lot myself but certain things (eg replacing a
transmission or brain surgery) I wouldn't attempt.

Marc
1990 Audi 100 NF
non-turbo
non-quatro
non-running
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