Fuel pump in fuel tank

[Andyase]

Hi all

A couple of times in the last week my 2005 A6 3.0tdi quattro has just cut out for no reason, twice while I was breaking and once when normal driving.
Last week the battery was flat when I went to start one morning, after I had a power pack start it recharged to full in a day.

Today after it cut out it would not restart, it was turning over and eveything seemed to be working but no firing.

I called out breakdown and the chap found no fuel coming from fuel tank pump (under back seat) there was no pwer to pump, the fuse is ok but no power to fuse. He got it going by temporary wiring a live to the fuel pump fuse.

Does anyone know if a relay feeds the fuse for the pump and where it is?

any help appreciated.

Andy

[gupsterg]

There is a fuel relay J17 it is located in the plenum chamber guides say left side, image highlight in line with steering, car is LHD in guide and sometimes these thing are in mirror position as our cars are right hand drive, a fuse SC1 is also on circuit again guide shows on right side of dashboard...

Please allow for errors as I am a to using this guide and interpreting...

But I will double check tomorrow if not raining and post back with photos if you want
Mine is also a 3.0 TDi on 55 plate, Sep 2005...

Just in case you don't know how to access plenum chamber... remove rubber strip/seal in red box, lift cover...

Attachment 17195

Fuse SC1 (first fuse) is in ST2 (brown fuse carrier 2nd row of holder) as image of car LHD in guide... will photo & post
J17 is 3rd slot relay holder in plenum chamber electrics box and I think on right when viewing standing at front of car, as image of car LHD... will photo & post

Please allow for errors as I am a to using this guide and interpreting...

Well fuse is on passenger side of dashboard... highlighted in red below images...

Attachment 17208Attachment 17209

Well it looks I'm stuck as do not have wiper arm puller to remove wiper arms to remove plastic cover below them to gain access to last screw holding cover onto plenum chamer electrics...

[Andyase]

I have removed rubber strip and plenum cover, I cannot remove all screws on the electric box due to the plastic strip at the bottom of the windscreen. The strip looked to be glued on? anyone know how to remove the strip?

I managed to open the electric box and can see there is some water in the bottom, there are what looks like 2 relays, the wiring at the bottom is semi covered with water and the relay with 314 printed on it looked to have some green corrosion at the bottom.

[gupsterg]

Have you removed wiper arms??

[Andyase]

I tried but could not get them off, any tips?

[gupsterg]

Even if you get last screw off... which I did by using a stubby handle and torx bit...

Here's a poor view of left chamber...

Attachment 17217

At the rear of these lids is a catch system which only allows lid to be removed if you can lift fully from front, which only doable if wiper arms removed, then wiper motor cowl (the black trim your referring to)...

I did not post photo/experience as I thought you read by last line in 2nd post

Well it looks I'm stuck as do not have wiper arm puller to remove wiper arms to remove plastic cover below them to gain access to last screw holding cover onto plenum chamer electrics...

Link:- Silverline Windscreen Window Wiper Arm Removal Puller Tool Glass Mechanics | eBay

I've just ordered one of these... I once needed one when did some work on rear wiper motor as mine an Avant... but did not need in end... but I think needed in garage now

As it started raining I quickly screwed everything back together and left it A local tool shop near you may have one...

You will note on the wiper arms there is a notch to place flat head screwdriver to lift caps, then undo nut, use puller to remove arms, two screws at front edge in centre hold cowl on then remove to gain good access...

I would not try to force anything you may do more damage then you want...
Hope you don't take offence I always find it's better to leave a project until all tools at hand...

If you got water plenum chamber electrics you really need to get good access sort everything... make sure drains in bulkhead are clear...
I'm surprised that you have not experience more electrical problems
But at least you will remedy your current issue and stop any further one occurring

[Andyase]

Ill order a puller, but in the mean time ill have a go at manually loosening it.

And if i look from the front of the car the box with water is the right hand side!

[gupsterg]

In guide fuse SC1 is located on right hand side of dash as that is passenger side in LHD car... but as our car RHD and passengers side is on left the fuse is actually there...

Therefore if apply same logic I was checking left because guide always assumes left hand drive car and in image they showed plenum box right house J17 Relay hence I check left...

I usually buy better tools but silverline compared to the sealey one I saw seemed more compact, plus likely chance gonna use less compared to say a torque wrench...

But anyway at least you know where to look...
You know what tools needed and some method of approach...

Ill order a puller, but in the mean time ill have a go at manually loosening it.

Maybe some penetrating oil eg WD40... hope you not take offence but take it easy as seen posts where damage can occur by forcing..

And if i look from the front of the car the box with water is the right hand side!

I would check both as one houses car ECU... do not removing cabling to ECU... can't say what would happen but guide discourage this... it can be lifted out to view housing for water, not sure but I think that also has some fuses/relays below it will check post back...

[Andyase]

Thanks for the tips.

I have ordered the wiper removal tool. I have removed half a pint of water with a squeeze bottle i had that had a long tube. Thinking about it now, when it cut out while breaking, it must have rocked the water over the contacts and shorted. So when i get the tool i can replase the 2 relays in there and redo the connections, which i can see are corroded.

Below is the temporary fix that powers the in tank fuel pump.


Capture.JPG

[gupsterg]

Reading the post in the thread you've found and resurrected it seems as if image in guide right...

Relay would be in box on right when standing in front of engine bay...

Wish blinking guide was not as confusing as somethings mirrored like fuse others not...

Anyway for someone in future who only find this thread link to other thread with very good posts LINK:- A6 3.0 TDi Quattro - Multiple Electrical Problems including cutting out

2 relays in the base of the box that had been submerged and were corroded. One is fuel pump relay....