John Gaffigan

I've thrown several parts into my 2001 fuel housing - new VDO fuel pump plus the $200 gasket kit...which didn't include the large O ring. Also, the wiring assembly to activate the pump has too much resistance. I'm wondering if I should just get the whole damn assembly - part # 4D0 201 743E. Anyone have a slightly used (but working!) 4D0 201 743E assembly for sale at a reasonable price? I'm getting buried with expenses on this car. Love it when it runs...hate it when it doesn't!

audijim113

I sent you a PM

BrianC72gt

Undo the banjo bolt on top of fuel pump assembly in the trunk. Go find a hose barb with a matching thread. Tricky to find. Speedshop or hydraulic place? Thread it in. Add 6 feet or so of cheapo clear gas rated plastic hose. Cheap stuff, gas rated, cheap clamp.

Remove passenger footwell carpet, remove mdf relay box cover(4 screws), slide out relay tray for fuel pump (1 screw). Pop plastic cover off of FP relay. With ignition key turned to RUN, push the relay points closed with a folded up matchbook cover or a piece of that cheapo plastic hose or anything at all and the pump will run continuously. Now you just use the key to toggle the pump on/off.

Run it until the tank is empty.

Pour 2 gallons back in. Get nearly all of it back out? You're GTG.
If you get nothing at all, then the hose from the fuel filler is unclipped from the top of the cup assembly. When you fill up, gas is directed into the cup and spills over below to the rest of the empty tank.

If you get maybe a pint (the original prime to the cup) and then then nothing then:

1. your suction port is not lined up inside the assembly (the male side pipe on removable portion did not mate to the female portion cup at bottom of tank);
2. wrong pump - a really common problem. the correct weird pump has extra port at the bottom.;
3. replacement pump hose or clamps are ****e;
4. suction hose(s) inside tank is unclipped from underside of cup assembly inside tank. Squeeze to remove with pliers. Reshape the end because it is out of round and push firmly to re-attach feeling a positive "click" lock. pull to confirm.
5. sketchy install wiring - never heard of it until you mentioned it, but sure, I suppose that could happen.

Do this and you have ZERO guesswork. The pump either works right or it doesn't. Otherwise you are lobbing random parts and pissing in the wind.