[V6-12v] Fuel Pump Replacement- knurled turkey head method

[Sean Coriaty]

Caution: verbosity ahead.
Folks,
Hit an uninsured telephone pole w/ my prized 200 20v avant in a long
sweeping left hander w/ 5-inches of snow and a bit too much velocity
and confidence in Quattro w/ cheap snows.  Needing a quick
replacement, got a black on tan '94 100CS Quattro sedan ($1350, needed wheel
bearing, well kept, faded paint, 184k).  Won't go into the differences
between the blown I-5 and the V6, or the 5-speed vs. the 100's auto but the
100 is still a fine Audi.
Anyway, the 100 wouldn't start Saturday morning- or would start, struggling
to idle before dying; any touch of gas pedal killed it instantly.  Then it
suddenly started normally and ran fine.  Began the 90-minute drive home.
Hit 100 MPH briefly on highway w/ no problems- just smooth power.  Got to
the end of the off-ramp, light turned green, gave it gas, and stalled
mid-intersection- never to start again.  Threw it in neutral and coasted to
safe piece of shoulder.
Suspected fuel pump, though it had never made a peep.  Certainly no bee
hive noises.  Checked relay and fuse and electrical connection on plastic
tank cover for 12 volts with ignition on w/ multi-meter.  All good. Followed
fuel lines from motor fuel rail, saw no pump, determined it had to be
in-tank.
Thrilled to find the fuel tank access hole cover after pulling the carpet
down from the upper level of trunk.  Removed 3 screws around the trunk trim
piece, saw the electrical and fuel line connections in a round plastic part
sealed into top of fuel tank and thought I had it made (no tank drop
required).  Called parts stores roadside- not many options at 3:00 in the
New Hamshire woods on Sunday.  Finally Pep Boys claimed to have one in the
metropolis of Manchester- paid $299 for Carter Federated Mogul Fuel Pump #
P72105.  Surprised to see Bosch: Made in Czech republic on pump.
Removed connections under access cover, removed plastic plate and found gas
gauge sending unit w/ float-arm contraption attached.  Had to pop the
plastic ski sack out using 2 screwdrivers from inside car to pry bottom of
plastic sack frame up, then pushing the sack/ frame assembly into the
trunk to provide trunk clearance to lift the sending unit straight up.  Once
out, saw no fuel pump.  Followed the fuel hose with a flashlight, and saw a
metal pump encased in layers of mysterious white plastic contraption w/ 2
wires and fuel hose attached...resting under 10 inches of fuel.  Method of
pump removal was not easily ascertained by visually analyzing the
contraption from 2 feet away, breathing noxious fumes and looking through
fuel refractions.  Stuck bare arm through the fuel and twisted and turned
and otherwise fanangled the plastic parts immediately surrounding the
pump.  15 minutes of this, it wasn't out, daylight was done, and so was I.
That night, checked online and found an apparently OEM Bosch unit advertised
for $128.  And pic looked different from the $299 Pep Boys "special".  Hmmm.
Checked this list and found this thread:
http://www.audifans.com/pipermail/v6-12v/2006-July/001584.html.  Good info.
Checked SJM, got this picture post how-to for earlier C3 10V turbo models:
http://www.sjmautotechnik.com/trouble_shooting/10Vfuelpumpnew.htm.
Interesting.  White contraption looked very similar and learned about Audi's
Special Tool # 3214.  Reminded of hatred for special tools.
Checked the pirated Mitchell Audi CD  I'd recently got off eBay and learned
absolutely nothing.
Lamented lack of Bentley.
Next morning, pumped 8 gallons of fuel out of tank to remove yesterday's
contact biohazard (highly recommended).  The vapor-breathing biohazard seems
unavoidable without SCUBA gear (OK, I'm sure there's a simpler mask type
filter that would work).  Decided to remove the plastic contraption similar
to SJM's technique but using the July 2006 V6-12V lister's screwdriver and
mallet method to bypass the Special Tool.  Banged, banged, banged, it
wouldn't turn.  By this time, yesterday's blind mangling-fingers method of
removal attempt had loosened the pump in the plastic nest.  That was
a mistake.  Visually inspected again, and discovered "The Method".  Trick is
to pull only the pump, leaving every bit of plastic contraption mounted to
bottom of fuel tank.  Once method is discovered, it's incredibly simple.
Got no pics, but here's how it's done: First, look carefully at picture #7
of SJM's site (close-up of plastic contraption).  Notice inner cylinder,
into which the pump slides.  Notice lip of cylinder- there is a screened
nipple sticking up.
But on my 1994 Audi 100CS Quattro, there were 2 other plastic pieces
sticking up from rim of that cylinder.  If screen is at 12:00, these pieces
stuck up from 3:00 and 9:00.  They are difficult to describe.  About 3/4
inch high, 1/4 inch wide and shaped like a turkey's head and neck.  Turkey's
"Beak"  was flat plastic while turkey head and neck were knurled (had
plastic ridges/ grooves).  I had noticed these the day before and attempted
to remove pump in plastic by pinching these 2 protrusions together and
lifting up.  Wrong.  The trick is to spread the "turkey heads" apart,
concentrating on moving the "beak" away from contacting the top edge of the
pump, which completely frees pump to be easily pulled straight up w/ all
plastic remaining untouched at bottom of tank.  Done in 5 seconds, no
banging, no special tool.
Pep Boys' "Special" $300 pump was far from correct part.  Dover Auto World
(Audi Stealership) sold me the correct pump for $173.75 that had no visual
markings on it (but did have Audi sticker on box.  Old (failed) pump has
following numbers stamped into body:
BOSCH: 0 580 453 070
AUDI: 8 A0 906 091 A
New pump (not marked) sticker on box reads: 8A0906091G, Pumpe BG, 1 Stueck,
Expire Date: <nothing written>, Charge:  29 Sep 2005 (stamped), Made in
Germany.
Parts invoice reads: 8AO-906-091-G, Bin number 142F01.  Price: $173.75
Wonder if the hand-stamped date corresponds to the "Expire Date:" written on
label or "Charge:" written below (though it's mostly lined up with
"Charge:").
Box manufacture date reads "07/05"
Hook the new pump up and it simply slides right back into place.