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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
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    russwuss Active Member

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    [Jan 12, 2014]
    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%"]

    [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]


    [/TABLE]
    #1
    Sam_, Alex C, Nilz and 6 others like this.
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  3. limbo118118
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    limbo118118 LORD

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    [Jan 12, 2014]
    not something im doing personally but very good write up! :)
    #2
  4. m19lte
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    m19lte Member

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    [Jan 12, 2014]
    Great write up, how much was the pump ?
    #3
  5. epox
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    epox Active Member

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    [Jan 12, 2014]
    Nice one! Would be good if admin could put it in the stickies.

    Mark
    #4
  6. JimS3
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    JimS3 Active Member

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    [Jan 12, 2014]
    £110.85.

    Good price, Nice find!
    #5
  7. russwuss
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    russwuss Active Member

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    [Jan 12, 2014]
    Thanks for the positive feedback, I tried to get more pics but my hands were so cold.

    Pump was £110, free 48hr postage.
    #6
  8. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Jan 12, 2014]
    Worth a sticky
    #7
  9. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    [Jan 12, 2014]
    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!
    #8
  10. m19lte
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    m19lte Member

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    [Jan 12, 2014]
    bargain, I'll remember this one :)
    #9
  11. Lavis89
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    Lavis89 Active Member

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    [Jan 12, 2014]
    Brilliant write up, kudos.
    #10
  12. vfr800
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    vfr800 Active Member

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    [Jan 13, 2014]
    Nice one! Thanks very much for the super write up.
    #11
  13. Gops
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    Gops 6th gear @7000rpm

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    [Jan 13, 2014]
    Nice! I loved inhaling the VPower lol! Got high as a kite!
    #12
  14. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 13, 2014]
    Added to the FAQ sticky... just in case somebody decides to actually go there!

    Nice write up btw :)

    <tuffty/>
    #13
    sssline, russwuss and vfr800 like this.
  15. Sam_
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    Sam_ Down under

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    [Jan 14, 2014]
    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!
    #14
  16. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    [Jan 25, 2014]
    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 :)
    #15
    russwuss likes this.
  17. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    [Jan 26, 2014]
    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.
    #16
  18. Sam_
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    Sam_ Down under

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    [Jan 27, 2014]
    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.
    #17
  19. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    [Jan 27, 2014]
    Good good that makes me feel a lot better :)
    #18
  20. russwuss
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    russwuss Active Member

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    [Jan 27, 2014]
    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.
    #19
  21. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    [Jan 27, 2014]
    Yeah will pop the cover off tomorrow and get a pic of how its installed in mine :)
    #20
  22. vrbob
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    vrbob Thats no Moon, Thats a space station!

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    [Jan 28, 2014]
    Piccy of how pump looks in my car

    Fuel Pump orientation.jpg
    #21
  23. russwuss
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    russwuss Active Member

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    [Jan 28, 2014]
    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!
    #22
  24. JoeeS3
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    JoeeS3 Active Member

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    [Mar 10, 2014]
    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
    #23
  25. russwuss
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    russwuss Active Member

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    [Mar 10, 2014]
    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!
    #24
  26. david7m
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    david7m Member

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    [Mar 10, 2014]
    I ruined my fuel pump by forgetting to replace the fuel filter :(

    Dave
    #25
  27. Machine212
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    Machine212 Member

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    [Jul 8, 2014]
    I'll be changing mine this weekend. Will the guide still be obvious to follow with the few broken image links?
    #26
  28. Drue1
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    Drue1 Member

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    [Jul 21, 2014]
    Is it an uprated or standard pump ? Can you buy an uprated one to fit into the standard place
    #27
  29. russwuss
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    russwuss Active Member

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    [Jul 22, 2014]
    I've read not.. A lot of people run standard pumps plus an extra pump where the fuel filter is...
    #28
  30. mattyboy199
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    mattyboy199 Active Member

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    [Sep 4, 2014]
    Chaps i have my new pump & plan to swap them over this weekend, can anyone confirm size number of jubilee clips i will require ?
    #29

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