
Originally Posted by
jjvwg
I think it has to do with the shape of the gas tank though and how the gas moves between the two halves of the tanks. Audi says to be 1/4 tank or less when removing the pump and when I did my b6 I was just over a 1/4 tank and still had gas right at the top with a little spillover. Unfortunately even though WorldPac is delivering today they haven’t brought my parts yet
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I've had to deal with this quite a bit lately. On the B8s, just under 1/2 tank will be right at the brim of overflowing. If the LPFP still primes you can attach a hose to the same spot as the fuel send line and let the pump do the work for you. This line is under pressure though, so to avoid a mess, unplug the wiring harness from the fuel pump (or pull the fuse/relay, whichever) and start the car for a second. The HPFP will pull the remaining fuel out of the low pressure line so you can pop it off the LPFP without spraying everywhere...just be sure to kill the engine before it dies on it's own from lack of fuel.
When removing the LPFP assembly there will be a good amount of fuel still trapped in the pickup and filter. Have a lot of towels handy so it doesn't drip on your paint. Get a bucket close by to catch the rest as it drains out.
If you're replacing the controller too, now is the time, as there isn't enough space to remove it with the pump's lock ring on. Unscrew it and use the cable loom to help guide it around the pump access hole closest to the front of the car - this is where you have the most clearance between the tank and body of the car. You'll have to get it to the other side of the fuel send line, careful not to crimp it.
When buttoning everything up and putting the lock ring back on, make sure the number 1 rib (the spot with 3 ribs close together) starts at the 10 o'clock position. It will spin about 1.5 times, and be fully locked when the number 1 rib is at the 6 o'clock position; you may or may not be able to get it back to this position with a flathead and hammer without breaking ribs.
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