The Audi guy has done something wrong when refitting the new pump. The fuel delivery mechanism on the D2 is quiet complex, and to refit the fuel pump properly requires a great deal of skill to get it working correctly.
The tank has two parts, and the fuel pump as well as pumping fuel to the engine also needs to get the petrol from the other half of the tank. The first symptoms you describe RE: chugging at low fuel level are indicative that the pump was not refitted correctly and could not properly pump fuel from the passenger side of the tank to the engine. The result could be the pump running dry and thus eventually seizing up because it overheated.
This youtube video shows how to install the pump and how complex it is to do it blind.
https://www.youtube.com/watch?v=no5K...A&spfreload=10
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Manny
2004 A4 1.8T Sport Cabriolet, 89K Miles
Past
2004 D3 A8 3.7 Quattro, Xenon, Bose, Blinds, Solar Sunroof, TV, ACC, phone and almost every option. 168K miles rising slowly
with retrofit AMI and DVB-T in place of Analogue
2003 Volvo S60 D5 SE Manual, 197K miles.
2001 D2 A8 3.7 QS, Bi-Xenon, Bose, Blinds, Electric Everything, retrofitted RNS-D, 191K Miles
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