Fuel Pump: Service and Repair

Fuel Tank Assembly:

1. Relieve fuel system pressure.
a. Open trunk and remove floor covering.
b. Remove fuel tank cover (floor of trunk).
c. Disconnect fuel tank electrical connector.
d. Start engine and run until it dies.
e. Carefully loosen one hose connection at the fuel filter. Cover with a clean rag when doing so to avoid spraying fuel if any pressure remains.

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.

Removing Fuel Gauge Sending Unit Locking Ring:

2. Using tool #VAG-3087, turn sending unit lock counter-clockwise and remove locking ring.
3. Lift out sending unit.

Fuel Pump Removing/Installing Tool:

4. Reach inside tank with tool #VAG-3214 and an extension, and turn pump housing counter clockwise approx. 15°-20° to unlock pump from bracket.
5. Pull pump up to remove.

6. Install in the reverse order.

NOTES:

Aligning Fuel Pump In Baffle (Quattro Models):

When installing pump in tank of front drive only cars, align pump in baffle so that the single V mark lines up with mark on baffle.

Aligning Fuel Pump In Baffle (Quattro Models):

When installing pump in tank of four wheel drive cars, align pump in baffle so that the double V mark lines up with mark on baffle.

Lock pump in place by turning clockwise with tool #VAG-3214.