Jan 20, 20214 min read

Audi A6 C5 Fuel Pump Replacement

I got with me here an Audi A6 that has a dead fuel pump and I’ll be showing you how to replace it without any special tools.

STEP 1: Make sure that the battery is disengaged from the vehicle to prevent any sparks.

STEP 2: The fuel pump for this vehicle is located underneath the rear passenger seat cushion.

-To remove it, all you have to do is firmly pull up on either side of the seat cushion and it should pop right out.

STEP 3: There are two black covers that look identical, however the fuel pump is located on the one with an electrical wire running from it.

-The cover is held down with 3 Phillips head screws that need to be removed

STEP 4: To prevent all this dirt from entering the fuel pump, it's a good idea to first clean up around the fuel pump cap area.

STEP 5: Alright, now to remove the connector, gently pry up on the plastic tab while pulling the connector out.

STEP 6: To remove the fuel line clamps, gently wedge a flat head screwdriver in between the clamp and twist until it is broken free.

-Now gently twist and remove the fuel line with a nose clamp plier. Although I didn’t do this, I would recommend that you wrap the plier with electrical tape to prevent damage to the lines.

STEP 7: Once removed, label the fuel line with the appropriate arrow to help you during installation.

STEP 8: To remove the lock ring, use a screwdriver and hammer then tap the edge of the ring counter -clockwise in order to remove it.

STEP 9: Pull up on the cap, remove this rubber gasket, and I disconnected these two wires from the cap.

STEP 10: Alright, this next part was my homemade solution to substitute for Audi’s expensive special tool that they say is required to remove the fuel pump.

*However, if you want I did find a similar tool for only $18 on Amazon here's the link.

-Fuel Pump removal tool for Audi, VW, Mercedes, BMW, and Chrysler : https://amzn.to/37xC6q3

-All I did was grab a metal panel clip tool and a long wrench but you just need two wrenches that are fairly long.

Then just hold both in a criss-cross position like this on the given slots and turn the pump counter-clockwise until disengaged from the lock.

-Now pull up on the pump to make sure it is free

STEP 11: Next, for the pump to be removed you need to remove this fuel line from the cap remove the clip with a flat head screwdriver and twist off the hose with pliers making sure to wrap the pliers with electrical tape to prevent damage to the hose.

-With that out now you can move the hose to the side and finally remove the pump from the tank.

-Although this part is not required, I manually pumped out the remaining fluid from the tank so I could remove some dirt at the bottom of the tank. And also so it would be much safer while working

STEP 12: Okay, now bring your pump to the bench and remove the hose connected to the pump

-Then, remove the two electrical wires

-Now, bring your new part and inspect to make sure it is similar to the original part

REINSTALLATION

STEP 13: First put the clamp over the hose and reattach to the pump here's the link to the correct clamp.

-Fuel line pinch clamp & tool : https://amzn.to/3dPOsLb

STEP 14: Re-attach the two wires which are different sizes so you can’t really mess up when reattaching

STEP 15: Bring the re-assembled new pump to the tank and place in the housing and turn until you feel it fall in the locking mechanism (when you it falls in you will feel it as you turn it from side to side.

STEP 16: Grab your homemade special fuel pump tool and repeat the same process as in the beginning however just turn clockwise until you hear it snap into place.

-Check to make sure that the pump is seated securely.

STEP 17: Place clamp over the hose, and then reattach the remaining hose to the cap

-Tighten the clamp

STEP 18: Re-attach the remaining two connectors as seen here.

STEP 19: Then, pull the rubber gasket over the cap and hoses and then press it into place around the opening.

STEP 20: Slowly bring the top piece down and readjust the hoses and wire so that the cap can be seated securely, then place the lock ring on top.

STEP 21: Finally with one hand pressing down the cap, turn the lock ring to this position and turn clockwise to secure the cap in place.

-Then come in with a hammer and screwdriver to securely tighten the top cap tight enough to make sure there is no fuel vapor leak.

STEP 22: Place the clamp over the hose, push the hose into the correct nozzle that was marked in the beginning, and tighten the clamp around the nozzle.