bennya8

Hello everybody, I have just attempted to replace the fuel pump on my 96 a8 4.2 quattro, however I am having great difficulty locating the pump back into position, I have removed the sender to make location easier but no matter what I do I cant seem to get the housing to line up with the housing in the bottom of the tank. Any help gratefully appreciated!

A8CT

do you have the Bentley or other instructions? You really need those but don't be afraid to work it into position. What I mean is you have to rotate the pump housing while pushing downward.

In the process, the pump jams up against the side of the tank so you have to "force" it past the high point so it'll drop down further. You'll hear some squeaking plastic but it will go. The whole thing is less than 30 seconds....


Bob

bennya8

thank you for your reply I have actually just managed to get it all back together however it was a mission! but now the car starts but wont rev up and won't run for long until it cuts out, the tank is approx 1/4 full, however i have read somewhere that you have to put plenty of fuel in when first put back together, is this correct? I have slackened the feed union at the top of the assembly and its seems to be pumping a lot of air with some fuel.

bennya8

Just to let you know, I have put another 5 gallon of fuel in the tank and it runs fine, when I have time I am going to extend the return line and put it into a large container and run the pump until the tank empties and then check the reading on the tank to make sure the tank is emptying fully.

A8CT

If it won't run on less than 1/4 tank, that means the pump is not seated correctly. The small tube on the side of the pump housing has to go into the other end on the pick up assembly in the tank.

It's a blind shot. I was able to rig up my borescope through the driver side fuel sender hole and "see" it go in but there's no way to do it otherwise.

It'll run fine otherwise as long as it's over a 1/4 of a tank (roughly).


Bob