Fuel pump replacement - notes

[A8CT]

I proactively replaced my primary pump (pass side) based upon almost 100k, a loud buzzing and a slightly rough idle. The new one seems to be as loud as the old one, I'm thinking it's because they went from plastic to metal tanks (D2-->D3). Took it for a about a five mile run and it seems fine. I know I've been bitching about working on the D3 but the pump setup is an upgrade for sure. I'm not thrilled with having two pumps but replacement is pretty straight forward. And, it seems like if it works, you're good. For those that have done the D2 fuel pump, there was an art to getting it right so you wouldn't run out of gas under 1/2 tank. Plus, everything was just under $300 shipped from Loree at Sunset Audi. A few comments: 1) 1/4 tank of fuel is recommended 2) It's a maze of hoses when you open it up but there all quick disconnects which makes it easy. Unfortunately, they put the connection for the secondary pump on the driver side so you have to open it up for that reason. This is the long hose which you'll see on the new pump. If they made the connection on the other end of the hose, everything could be done on one side. 3) The "fuel fill" is on the backside of the pump housing and blind going on and off. Bentley leaves out the step about reattaching it. It's a squeeze on each side and a push into the housing. One of those things where I'm not sure exactly how I got it off and then back on. Take a look at the connector and new pump so you see what I mean. 4) When you pull the pump out, the housing will have a LOT of fuel so plan that in advance. 5) Pay attention to the hose routing when connect everything together. I reconnected two fittings because I found that the hoses were getting kinked when I reinstalled flange. 6) The connectors will fall into the tank, there's not a whole lot you can do. You just have to fish around for them at the end. There are only 3 connectors per side but there's a spot for a 4th connector which doesn't exist. Thanks to Doug for sending me more details offline so I ordered the right pump and tool. --------------------------------------------------------------- My car is an '05, the correct part # is 3D0 919 087 L. You'll also need two of the rubber washers that go under the locking ring which are 1J0 919 133 B. I bought the lock ring tool which is Matra # T10202. You might be able to tap off the locking ring with a screwdriver and hammer but the tool does make it easy.

[A8CT]

BTW, the housing comes apart easily if the pump itself could be sourced it would be even cheaper.

A bunch of #'s on the side by no recognizable brand names.