1998 Audi A4 fuel pump replace

  • 1998 AUDI A4
  • 4 CYL
  • AWD
  • 150,000 MILES
How do I remove the return fuel line connector from the fuel pump flange
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have the same problem?
Saturday, March 13th, 2010 AT 6:32 PM

1 Reply

Push in the 2 plastic flanges to unclip the connector !

Removal & Installation (A4 Front Wheel Drive Only)
Observe fuel system warnings and notes. Turn ignition off and remove ignition key from vehicle. Disconnect negative battery cable. Working in luggage compartment, remove fuel pump access plate. Note orientation of fuel lines. Mark and remove fuel lines. Disconnect fuel pump and fuel level sensor harness connector. Using Union Nut Wrench (3217), remove union nut. Remove cover flange and "O" ring seal. Disconnect fuel level sensor harness connector from inside of flange cover. Disconnect return line from inside of cover flange. See Fig. 4 .


Insert Fuel Pump Wrench (3307) through opening in fuel tank, turn inner section of surge housing about 15 degrees to the left. Remove fuel pump assembly through opening. Remove supply line from fuel pump. Remove power and ground wires from fuel pump.
Install new fuel pump to inner surge housing. Connect power and ground wires to fuel pump. Connect fuel supply line to fuel pump. Install fuel pump assembly through opening. Place inner surge housing into outer surge housing so that notch (1) on inner housing matches mark (2) on outer surge housing. When installing inner surge housing an audible click should be heard when housing is seated. Using fuel pump wrench turn inner surge housing about 15 degrees to the right. Notch (1) on inner housing should now match mark (3) on outer surge housing.
Connect return line and fuel level sensor harness connector to cover flange. Using NEW "O" ring seal install cover flange. Install union nut, using union nut wrench torque nut to 44 ft. lbs. (60 N.m). Connect harness connector and fuel lines. Re-install cover plate. Connect negative battery cable. Reprogram radio, clock and power windows as necessary.
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Wednesday, March 17th, 2010 AT 7:59 AM

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