Fuel pump fuse fun

[Peter Golledge]

Listers,

Had a Fuel Pump fuse blow a couple of times in the 95 S6, figured with
120K+ miles under my ownership the fuel pump  had worn through brushes/slip
rings or some such.  Replaced pump, all was well for a few weeks, then back
to fuse blowing randomly.

Relayed the FP wiring to avoid known issues in that area, next test drive
blew the fuse on the new "under seat" relay circuit instead of the regular
fuse.  So at least I knew issue was in the tank.  Surgery was conducted
with 18 year old son assisting, easy since this is the Avant.  All looked
good from my viewpoint, fortunately young person eyes spotted some
insulation just worn through on the green/yellow (power) wire.  The wire
(zip tied to the fuel line) has been rubbing on the tank at times in the
last 241 K miles and finally got to the point where it would short to
ground on the tank body itself!  Slit some 3/8" fuel line along its length
and wrapped/zip tied over both wire and line to insulate and provide
protection against future abrasion.  Worth checking those wires very
carefully when doing fuel pump R&R on our aged Audi fleets!

Cheers

Peter Golledge