5KTQ: R&R fuel pump

[Steve Sears]

Louis,
The Bosch fuel pump has a check valve screwed into the top, sealed with a 
copper washer.  There is a copper washer on top of that, then the banjo 
fitting, and then another copper washer between the fitting and the "noise 
reducer" (which sorta looks like a hat).  Apparently Pierburg pumps have 
internal check valves and don't need the noise reducer.
The real bear of a line to remove is the banjo fitting on top of the tank - 
if it's been on there for a long time you may find that the metal socket in 
the plastic fuel level sender top will turn.  I used a big screwdriver 
between the banjo line and the electrical socket to free the bolt.
You can reuse copper washers - provided that you re-anneal them.  I did so, 
but was a long way from the car and my skin/clothes were gasoline free 
before I even thought about sparking up the torch (remember...gasoline fumes 
will fall and run along the ground/floor).  Like Kneale said, the shape of 
the tank will not allow you to totally drain it, and the fumes are more 
explosive than the liquid so a total draining by siphon will not make it any 
safer.  If you run out of fuel (like I did....pulling into the driveway from 
work after being stuck in a traffic jam....whew!), then the liquid level 
will be lower than the clips holding the pump in - so you can avoid sticking 
your hand into the nasty stuff.  When the pump is out, take a look in the 
bottom of the tank to see if there's any debris in there - there was some 
talk a while back about tank linings falling into the tank and starving the 
fuel pump - I've never seen a lined tank...the inside of my tank looks like 
plain ol' steel.
Of course, be careful with any source of ignition...or potential (like a 
trouble light) source...while the tank is open....plus the usual 
disclaimers.....
Cheers!
Steve Sears
1987 Audi 5kTQ - holding steady at a quarter tank.....pump quietly humming 
away
1980 Audi 5k
1962 and '64 Auto Union DKW Junior deLuxes
----- Original Message ----- 
From: "L DC" <ldc007usa at yahoo.com>
To: "Steve Sears" <steve.sears at soil-mat.on.ca>; <quattro at audifans.com>
Sent: Wednesday, April 12, 2006 3:20 PM
Subject: Re: 5KTQ: R&R fuel pump


> Looking at pictures of the fuel pump, only one line
> hooks up to it, correct?
>
> That line connects to the fuel pump check valve,
> right?
>
> Awhile bakc, a friend of mine and I removed a fuel
> pump out of a 5K CS at a junk yard and if I recall
> correctly, that fuel line simply connects with the
> check valve without any ring/clamps holding in place.
>
> Also, that fuel line appeared to be made out of
> plastic or something, or perhaps became of such
> appearance with age and because it was submerged in
> fuel for so long. The point is that it was basically
> impossible to pull the line out of the metal
> flange--check valve--so we simply cut the line off.
>
> If is the same set up, obviously, I won't be cutting
> the line off, but will carefully remove the fuel pump
> check valve instead?
>
> Also, what does the non-sparking brass drift tool look
> like and where can I get one?
>
> Do I really need it?
>
> I'm planning on draining the fuel tank completely
> before removal of the pump.
>
> Thanks again,
>
> Louis
>
>
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