1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

How To: Audi S3 Fuel Pump Replacement (The cheaper way...)

Discussion in 'A3/S3 Forum (8L Chassis)' started by russwuss, Jan 12, 2014.

  1. russwuss

    russwuss Active Member

    Joined:
    Feb 7, 2013
    Messages:
    540
    Likes Received:
    100
    Hi All,

    Took the plunge and decided to swap the fuel pump on my Audi S3, car was struggling to start in morning especially when the tank was less than 1/4 full - I've borrowed some photos and instructions from here Step-by-step fuel pump replacement - AudiWorld Forums so credit goes to him - I just provided the photos of building the new pump.

    First off, i brought the pump from here Fuel Pump VDO - 993-745-117Z for your car lowest prices - Engine compartment - Air/Fuel feeding system - Fuel Pump - Fuel Pump - 993-745-117Z - strangely it doesn't come up when I enter my reg no, but does when you select your car as an Audi TT 225 :-/ but believe me it does fit! It's exactly the same pump as what's listed at ECP, just cheaper :)

    I must say, it's a lot easier than I thought it would be! Took about 1 1/2 hours in total, if your mechanically minded you will find it a piece of **** (my brother did ;-) )

    So here's when it arrived

    [​IMG]
    Untitled by russwuss, on Flickr
    [TABLE="width: 100%"]
    [TR]
    [TD="width: 100%"]
    Now for the instructions :)

    Step 1: Put out your cigarette.

    Next, disconnect the negative ground of the battery -- I suppose this is optional, but probably a good idea since sparks are not preferred when working around gasoline.
    [​IMG]

    Remove the rear seat bottom. It is held in by two clips, so just yank up on it sharply and it should unclip. (This is also a good time to vacuum out all the **** that has collected between the seatbacks and bottom.)
    [​IMG]

    [​IMG]

    The quattro actually has two pumps: The secondary pump moves gas from the left side to the right, over the differential that sits under the middle of the tank. The primary pump is on the right (passenger) side. Unscrew the three screws holding the cover.
    [​IMG]

    Pry off the electrical connector for the pump.


    Remove the two hoses. They each have a button that presses in, which allows the connection to lift off. (Screwdriver tip is touching it in this pic.) Have a few rags ready, since supposedly these are under pressure, but my car had been sitting a while so nothing really came out when I pulled off the connectors.
    [​IMG]

    Pay attention to the two arrows in this pic -- one on the pump and one on the fuel tank (where I wiped the dirt away). These need to be lined up when you put your new pump in.
    [​IMG]

    Next remove the big threaded nut that holds the pump in. Audi has a special tool for this, but I placed a flat-bladed screwdriver on one of the lugs and tapped on it with a hammer, which rotated it off. The pump should pop up when the piece comes off.
    [​IMG]

    [​IMG]

    Lift the top of the pump off and remove the rubber gasket.
    [​IMG]

    Reach inside and disconnect the plug for secondary pump wiring harness. Disconnect the fuel line by pushing on the release button and sliding it off.
    [​IMG]

    Next there is a plastic bracket that needs to be unhooked from the pump. It holds the secondary pump return hose. You have to reach pretty far in the tank to get at it, but it slides up and off the pump. You can see it on the right side of the pump in this shot.
    [​IMG]

    Now you can work the pump out of the hole. Have a bucket ready to put the pump in, since it may still have gasoline in it that will leak all over. Make sure you use an official Audi bucket; no other bucket will work for this...
    [​IMG]

    Grab the old and new pump, here's a side by side shot

    [​IMG]
    Untitled by russwuss, on Flickr

    Unplug the yellow and black pins from the top of the old fuel pump

    [​IMG]
    Untitled by russwuss, on Flickr

    With that done, you want to remove the pipe furthest to the left and pipe furthest to the right from the old pump, take your time... a little heat onto the hoses may help remove them.

    [​IMG]
    Untitled by russwuss, on Flickr

    Unscrew the fuel sender from the old pump (4 x T20 screws) and screw it onto your new shiny white pump

    [​IMG]
    Untitled by russwuss, on Flickr

    Attach the hoses to your new pump like so and that's it!



    [​IMG]
    Untitled by russwuss, on Flickr

    Feed your new pump into the hole and start reattaching everything, including the plastic bracket, the secondary pump hose, and the secondary pumpwiring harness.
    [​IMG]

    Put on a new gasket. This gasket goes on the inside edge of the opening (which took a few minutes to figure out, since I didn't pay attention when I took it out).
    [​IMG]

    Replace the top piece.
    [​IMG]

    Replace your nut; tighten it up the same way you took it off. Make sure you line up the arrow on the pump with the arrow on the tank.
    [​IMG]

    Snap on the connectors.
    [​IMG]

    Reattach and tighten the battery cable, turn on the ignition, cross your fingers, and try to start it. Mine didn't start right away -- had to crank for a while until it finally caught, which I assume was due to a dry pump that had to prime itself. Replace the cover, clean everything up and put the seat back in.

    I was amazed at how quiet the new pump is. I guess my old one had been getting progressively louder but recently it was annoyingly loud. Now all I hear at idle is the low grumble of the Milltek -- much better![/TD]
    [/TR]
    [TR]
    [TD][/TD]
    [/TR]
    [/TABLE]
     
    Perplexer, Sam_, Alex C and 7 others like this.
  2. Google AdSense Guest Advertisement



    to hide this advert.
  3. limbo118118

    Joined:
    Oct 6, 2009
    Messages:
    438
    Likes Received:
    45
    not something im doing personally but very good write up! :)
     
  4. m19lte

    m19lte Member

    Joined:
    Oct 20, 2011
    Messages:
    123
    Likes Received:
    6
    Great write up, how much was the pump ?
     
  5. epox

    epox Active Member

    Joined:
    Oct 13, 2012
    Messages:
    718
    Likes Received:
    50
    Nice one! Would be good if admin could put it in the stickies.

    Mark
     
  6. JimS3

    JimS3 Active Member

    Joined:
    Mar 17, 2013
    Messages:
    736
    Likes Received:
    72
    £110.85.

    Good price, Nice find!
     
  7. russwuss

    russwuss Active Member

    Joined:
    Feb 7, 2013
    Messages:
    540
    Likes Received:
    100
    Thanks for the positive feedback, I tried to get more pics but my hands were so cold.

    Pump was £110, free 48hr postage.
     
  8. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp?

    Joined:
    Jun 19, 2009
    Messages:
    3,712
    Likes Received:
    474
  9. vrbob

    vrbob Thats no Moon, Thats a space station!

    Joined:
    Jun 19, 2007
    Messages:
    2,375
    Likes Received:
    170
    Good work fella!

    glad the (French) pump did what we thought it would.

    Defo on my list to do and this also confirms that the VDO Fuel Pump part number - 993-745-117Z is identical to the ECP version.

    Thanks for the write up and guide to buddy that will defo help the masses and yup defo add to the stickies!
     
  10. m19lte

    m19lte Member

    Joined:
    Oct 20, 2011
    Messages:
    123
    Likes Received:
    6
    bargain, I'll remember this one :)
     
  11. Lavis89

    Lavis89 Well-Known Member
    Regional Rep Audi A3

    Joined:
    Aug 18, 2011
    Messages:
    1,178
    Likes Received:
    255
    Brilliant write up, kudos.
     
  12. vfr800

    vfr800 Active Member

    Joined:
    Feb 28, 2012
    Messages:
    750
    Likes Received:
    49
    Nice one! Thanks very much for the super write up.
     
  13. Gops

    Gops 6th gear @7000rpm
    Gold Supporter Audi S3

    Joined:
    Nov 6, 2009
    Messages:
    2,849
    Likes Received:
    399
    Nice! I loved inhaling the VPower lol! Got high as a kite!
     
  14. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

    Joined:
    Sep 14, 2008
    Messages:
    18,248
    Likes Received:
    2,413
    Added to the FAQ sticky... just in case somebody decides to actually go there!

    Nice write up btw :)

    <tuffty/>
     
    sssline, russwuss and vfr800 like this.
  15. Sam_

    Sam_ Down under

    Joined:
    Mar 8, 2011
    Messages:
    2,939
    Likes Received:
    417
    I done this myself recently but I always forget to bother taking pictures or writing a guide. It's pretty easy to do just fiddly. The only hard part if you re-use the top part and level sender is getting the hoses off the old pump. A bit of heat helped there though.

    Nice one for writing a guide!
     
  16. vrbob

    vrbob Thats no Moon, Thats a space station!

    Joined:
    Jun 19, 2007
    Messages:
    2,375
    Likes Received:
    170
    I bought one of the French VDO pumps last week as my car often starts a bit funny so as its on 120K and been running more than stock bhp for a while now I thought it best to swap out the old pump for a new one.

    Didn't take too long really probably an hour and half, worst bit was getting the little connector that slides off off the pump off. as you cant take the unit out of the tank without this removed. Managed to get it off and remove the pump swapped over all the bits from old to new and then reversed the process which was even more fiddly to get that connector back on the pump as you have to almost do it blind with your hand stuffed in the tank.

    Once back together took a couple of cranks to prime the pump and then starts straight up so jobs a goddun :)
     
    russwuss likes this.
  17. vrbob

    vrbob Thats no Moon, Thats a space station!

    Joined:
    Jun 19, 2007
    Messages:
    2,375
    Likes Received:
    170
    Just a quick heads up,

    I have re read the above guide and the bit where it says the arrow on the pump must align with the one you can find on the car did not apply in my S3.

    I remembered the way the pump was when I removed it as the 2 lines ontop were on the left hand side (if looking out the rear window) and the eleccy connector on the right.

    I was worried that I had re fitted the pump wrong so have re visited it today and the arrow on the car is 90 degrees away from the one on the pump. I have taken it all apart again (I stink of v power lol) and the float that indicates fuel level is the part dictating where the pump can go. This means I cannot align said arrows as the float hits the tunnel with the propshaft.

    I have put it back the way I found it with the arrows 90degrees out and it seems to be working as expected and my fuel gauge is showing the correct level.

    I shall run the tank down as low as poss and then refill to make sure the gauge has full range.
     
  18. Sam_

    Sam_ Down under

    Joined:
    Mar 8, 2011
    Messages:
    2,939
    Likes Received:
    417
    I did the same. Totally forgot about the arrow and just used common sense to put it back how it was. The fuel levels were fine afterwards.
     
  19. vrbob

    vrbob Thats no Moon, Thats a space station!

    Joined:
    Jun 19, 2007
    Messages:
    2,375
    Likes Received:
    170
    Good good that makes me feel a lot better :)
     
  20. russwuss

    russwuss Active Member

    Joined:
    Feb 7, 2013
    Messages:
    540
    Likes Received:
    100
    Sorry that's my fault, the pump part was lifted directly from the Audi TT instructions.. If you take a pic of where the pump is sat on your car I'll update the thread and check to see if mine is right.. Apologies.
     
  21. vrbob

    vrbob Thats no Moon, Thats a space station!

    Joined:
    Jun 19, 2007
    Messages:
    2,375
    Likes Received:
    170
    Yeah will pop the cover off tomorrow and get a pic of how its installed in mine :)
     
  22. Google AdSense Guest Advertisement



    to hide this advert.
  23. vrbob

    vrbob Thats no Moon, Thats a space station!

    Joined:
    Jun 19, 2007
    Messages:
    2,375
    Likes Received:
    170
    Piccy of how pump looks in my car

    Fuel Pump orientation.jpg
     
  24. russwuss

    russwuss Active Member

    Joined:
    Feb 7, 2013
    Messages:
    540
    Likes Received:
    100
    Thanks, mines the same as the photo! However slight problem..... my edit rights have been removed for the post :-(

    Could a mod quickly swap the last picture for the one posted above please?

    Thanks!
     
  25. JoeeS3

    JoeeS3 Active Member

    Joined:
    Apr 1, 2013
    Messages:
    464
    Likes Received:
    104
    Hi russ, was your old fuel pump making an annoying humming noise on idle? and did it feel like the car misfired a little when starting up? have a feeling mine is on its way out
     
  26. russwuss

    russwuss Active Member

    Joined:
    Feb 7, 2013
    Messages:
    540
    Likes Received:
    100
    Hi Joe,

    Yep that's right.. Had a strange ticking coming from the back of the car and it took a while to start.
    Logged my injector duty cycles as well and they were running above 100% after 5000 revs.

    Plus for the price it's piece of mind as well, last thing you want is the car running lean...

    Cheers!
     
  27. david7m

    david7m Active Member

    Joined:
    Nov 26, 2009
    Messages:
    514
    Likes Received:
    34
    I ruined my fuel pump by forgetting to replace the fuel filter :(

    Dave
     
  28. Machine212

    Machine212 Active Member

    Joined:
    Oct 29, 2013
    Messages:
    120
    Likes Received:
    30
    I'll be changing mine this weekend. Will the guide still be obvious to follow with the few broken image links?
     
  29. Drue1

    Drue1 Member

    Joined:
    Jun 18, 2014
    Messages:
    189
    Likes Received:
    23
    Is it an uprated or standard pump ? Can you buy an uprated one to fit into the standard place
     
  30. russwuss

    russwuss Active Member

    Joined:
    Feb 7, 2013
    Messages:
    540
    Likes Received:
    100
    I've read not.. A lot of people run standard pumps plus an extra pump where the fuel filter is...
     
  31. mattyboy199

    mattyboy199 Active Member

    Joined:
    Nov 13, 2005
    Messages:
    1,774
    Likes Received:
    17
    Chaps i have my new pump & plan to swap them over this weekend, can anyone confirm size number of jubilee clips i will require ?
     
  32. Jenno007

    Jenno007 Well-Known Member

    Joined:
    Feb 8, 2014
    Messages:
    1,063
    Likes Received:
    105
    Does anyone know the part number / where to buy the fuel pump filter (ie the filter before the pump, not the one that sits under the car). I have received my new pump and it says that you must change this when changing the fuel pump but gives no details...

    Cheers
     
  33. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

    Joined:
    Sep 14, 2008
    Messages:
    18,248
    Likes Received:
    2,413
    If its the pump listed above then its already in the unit... its a complete pump assembly and you only have to swap over the sender...

    <tuffty/>
     
  34. Jenno007

    Jenno007 Well-Known Member

    Joined:
    Feb 8, 2014
    Messages:
    1,063
    Likes Received:
    105
    I didn't buy the pump above

    I made the thread http://www.audi-sport.net/xf/threads/best-upgraded-in-tank-fuel-pump.229615/ and decided to go with the Deatchwerks pump as it is supposedly very good. However I don't want to ruin it by using an old filter.

    Do you know if I can just buy the filter from anywhere? Or is there anyway I can clean it out (presuming it's not damaged).
     
  35. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

    Joined:
    Sep 14, 2008
    Messages:
    18,248
    Likes Received:
    2,413
  36. Jenno007

    Jenno007 Well-Known Member

    Joined:
    Feb 8, 2014
    Messages:
    1,063
    Likes Received:
    105
    I would have thought they would sell just the filter.. Guess not.

    I presume you have changed many fuel pumps in your time. Is the filter just a sock? Could I replace it with something similar do you think?
     
  37. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

    Joined:
    Sep 14, 2008
    Messages:
    18,248
    Likes Received:
    2,413
    Not changed that many personally... as far as I know the filter is part of the container... not even sure they have a sock on these like others do

    <tuffty/>
     
  38. Jenno007

    Jenno007 Well-Known Member

    Joined:
    Feb 8, 2014
    Messages:
    1,063
    Likes Received:
    105
    Ahh great.. How stupid is that then, they say that the warrant will be void if you don't replace the filter, when the filter is part of the pump that they didn't supply.

    Anyway thanks for your help as always. I'll take it apart and have a good look (assuming I don't get too high from the fumes).
     
  39. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

    Joined:
    Sep 14, 2008
    Messages:
    18,248
    Likes Received:
    2,413
    Get some hand cream for afterwards too... having your hand in the tank will just sap all the oils in your skin and they will go dry and flaky for a few days...

    <tuffty/>
     
  40. Jenno007

    Jenno007 Well-Known Member

    Joined:
    Feb 8, 2014
    Messages:
    1,063
    Likes Received:
    105
    Ah thanks for the tip. Would rubber gloves work? Might buy some that go all the way up your arm!
     
  41. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

    Joined:
    Sep 14, 2008
    Messages:
    18,248
    Likes Received:
    2,413
    tbh you are better off without gloves unless you have a compelling reason to need to wear them... there are couple of fiddly bits to do in tank and you lose a little feel with gloves..

    Up to you of course

    <tuffty/>
     
  42. Jenno007

    Jenno007 Well-Known Member

    Joined:
    Feb 8, 2014
    Messages:
    1,063
    Likes Received:
    105
    Ah right. I'll try use as much fuel as possible before tomorrow then to keep the level low, wonder if the GF fancies going for a drive :p
     

Share This Page