My FUEL PUMP facts & findings (long)
 

1. There is only one fuel pump (not talking about the entire housing) that fits the D2. This fuel pump does not fit any other vehicle so if you go to an auto parts store and they cross reference and tell you that there's another pump that will work, DON'T listen.

2. The fuel pump # is VDO 405 052 002 001Z this is a Siemens which cross references with Audi part # 4D0 906 091 or 4D0 906 091C.

3.This fuel pump is NOT available in the U.S. it is available in Europe. I purchased mine out of England. Here
http://www.ignitioncarparts.co.uk/detailspage.aspx?searchStr=PFP405052002001Z
The cost was $255 and change. Depending on the value of the dollar, the price will fluctuate. It took about a week and the pump was at my door.

4. The new pump is perfect except for the connectors. There are bolts in place of your factory pull type connectors so there is splicing to be made and bolts to buy:
M5-0,8
M4-0,7 and lock washers for peace of mind.
3/16 (M5) or 4,76 mm (M5)

5. The pump is nestled inside the housing and it sits in a web of rubber tubing that is held togehter by plastic rings. I apologize for not taking pictures but focusing, concentrating along with the fear of braking one of these plastic rings took all my attention. I was surprised at how pliable the plastic was considering that it's been submerged in fuel for 10 years.

6. When you splice the cable be careful and pay attention because the polarities in the pumps are reversed. Yes, there is a positve and negative side to the connection.<ul><li><a href="http://www.ignitioncarparts.co.uk/detailspage.aspx?searchStr=PFP405052002001Z">http://www.ignitioncarparts.co.uk/detailspage.aspx?searchStr=PFP405052002001Z</a</li></ul>

how much
 

in labor is it going to cost to put in the fuel pump? do u have to remove gas tank?

Picture of pumps VDO on left, Bosch on right. Notice the difference in openings
 

<center><img src="http://pictureposter.audiworld.com/152346/sspx0467.jpg"></center><p>
This is the reason why the car staved after 7 gallons because the small opening in the VDO pump is the output that keeps the fuel circulating in the tank and filling the baffle.

Picture of the top notice the difference in connectors.
 

<center><img src="http://pictureposter.audiworld.com/152346/sspx0466.1.jpg"></center><p>This is the top of the pump of course.

These are the bolts one of them is bigger then the other, I believe it's the negative.
 

<center><img src="http://pictureposter.audiworld.com/152346/sspx0470.jpg"></center><p>

The fuel pump is accesible through an opening in your trunk. (passenger side)
 

<center><img src="http://pictureposter.audiworld.com/152346/sspx0471.jpg"></center><p>The procedure is relatively easy although I had to buy this special tool that is used to remove the locking ring that holds the housing.

If anybody needs to use this tool, you're more than welcome just pay for shipping.

quick, go burn off 9 gallons of gas!
 

can you do this blindfolded by now?

Great news, glad this one will do the trick. You definitley took one for the team....

Just to verify the connection:

The NEW pump has the bolt/nut terminals so you cut the old connector off and spliced ring terminals onto the wires.

How did you figure out that the polarity was reversed? Would the pump run backwards or not at all if you got it wrong?

Bob

Thanks for the FUEL PUMP facts & findings
 

We all really appreciate the effort and research you've put into figuring this out. Hopefully this will be the end of the '7 gallons and out' problem.

I've got a colleague ferrying a couple of the correct part number fuel pumps back from Germany sometime in the next couple of weeks-- if the function of the pump checks out, I should then have a spare unit if anyone on the list needs a replacement.

Thanks again!
TT

You mean VDO is on the left, right?