Well... an update on this issue since nobody replied...
took the pump out lastnight, the fuel tank had some black flack stuff in it, fished all that out with a net. the filter on the pump itself had some build up on the bottom and inside screens. Checked the actual pump itself to see if there was shaft play or any of the bushing where broken up on 12 volts and it handled fine. put the pump back together and WALAAA. no more noise. Just that when the system prime after starting the car I think that the fuel pressure regulator in the filter itself is having issues because it was making an awful sound. I checked the return line at the fuel pump and it was vibrating really bad. checked the out line of the pump and there was no vibration. Called AUDI and they said they will replace the filter at no cost since it is only 2 weeks old.
So any of you that are having pump noise and issues, I would suggest taking about 2 hours out of your day and breaking the things down piece by piece, its pretty simple. the only thing is on the FWD 1.8 that when you take the pump out, theres a clip on the actual pump housing inside the tank that has a hose and another one running off of it to the tank itself. That is you return line. Un clip it by putting two fingers inside the fuel tank and pull that line completely out. It took me awhile to figure on how to get the darn thing out. then after that is easy as cake from there.




