Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSAUDI1996A4 BASE, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 25 (ENGINE CONTROLS - REMOVAL & INSTALLATION)FUEL SYSTEMSFUEL PUMPREMOVAL & INSTALLATION (S4)
1996 Audi A4 Base, Standard
Removal & Installation (S4)
1996 Audi A4 Base, StandardSECTION Removal & Installation (S4)
WARNING: This page is about a different car, the 2002 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.
- Observe fuel system warnings and notes. Turn ignition off and remove ignition key from vehicle. Open and close fuel filler cap. Disconnect negative battery cable. See BATTERY DISCONNECT PRECAUTIONS under INTRODUCTION. Remove rear seat bottom, by lifting up and pulling forward. Remove right side fuel pump access plate. Note orientation of fuel lines. Mark and remove fuel lines. Disconnect fuel pump and fuel level sensor 4-pin harness connector.
- Using Union Nut Wrench (3217), remove union nut. Remove cover flange and "O" ring seal. Disconnect fuel level sender harness connectors from inside of flange cover. Disconnect return line from inside of cover flange.
- Working inside of fuel tank, press fuel line distributor connector on accumulator to left and pull upward to disengage. Release fuel return line from distributor connector. See Fig 2 .
- Insert Fuel Pump Wrench (3307) through opening in fuel tank, turn inner section of surge housing about 15 degrees to the left. Notch (1) on inner housing should line up with match mark (2) on outer surge housing. 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. 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 line distributor connector to accumulator. See Fig 3 . Using NEW "O" ring seal install cover flange. Install union nut, using union nut wrench torque nut to 89 ft. lbs. (120 N.m). Connect harness connector and fuel lines. Install cover plate. Connect negative battery cable. Reprogram radio, clock and power windows as necessary.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.