Fuel Pump: Service and Repair

WARNING: FIRE HAZARD! Disconnect battery ground strap when working on the fuel system. Do not smoke or create any sparks where odor of fuel vapor is present.

NOTE: Fuel tank should be less than half full. If tank needs to be drained, you can disconnect the fuel supply line at the filter, connect an extra piece of hose and energize the fuel pump to pump the fuel out of the tank. If pump will not operate, use a siphon pump and hose. Store fuel in a suitable clean container to re-fill tank after service is completed.

Fuel Tank:

FUEL PUMP REMOVAL

Fuel Pump Access Plate:

1. Open luggage compartment and remove floor covering.
2. Remove access panel for fuel pump and disconnect fuel pump and fuel gauge harness connectors.

Fuel Pump Lines:

3. Disconnect fuel supply line (banjo fitting), return line, and vapor hose.

Removing Fuel Gauge Sending Unit Locking Ring:

4. Using tool VAG-3087, loosen locking ring and lift the fuel gauge sending unit out of tank, being careful not to damage the wires.

Fuel Pump:

5. Disconnect fuel supply and return hoses from inside of sending unit housing.
6. Pull off electrical connection for fuel pump.

Fuel Pump Removing/Installing Tool:

7. Using tool VAG-3214, turn fuel pump housing approx. 15mm counter-clockwise to unlock pump.
8. Lift pump out of tank.


INSTALLATION

Fuel Pump Lock Ring:

1. Insert pump into tank housing with notch "C" lined up with mark "A".
2. Using tool VAG-3214 turn pump clockwise until notch "C" lines up with mark "B" (see illustration).
3. Remainder of installation is the reverse of removal procedure.