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.

Removal
- Disconnect the battery ground strap.
- Open luggage compartment and remove floor covering.

Fuel Pump Access Plate:

- Remove access panel for fuel pump and disconnect fuel pump and fuel gauge harness connectors.

Fuel Pump Lines:

- Disconnect fuel supply line - A (banjo fitting), return line - B, and vapor hose - C.
- Note the installation position (angle) of the fuel level sender for reinstallation.

Removing Fuel Gauge Sending Unit Locking Ring:

- 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:

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

Fuel Pump Removing/Installing Tool:

- Mount fuel pump removal tool 3214 to fuel pump in baffle housing.
- Turn fuel pump approx. 15mm (0.59 in.) counter-clockwise to unlock pump.
- Lift pump out of tank.

Installation
- Install in reverse order of removal, following the installation notes.

Fuel Pump Lock Ring:

Installation Notes:
- Insert pump into tank housing with notch "C" lined up with mark "A" (see illustration).
- Mount fuel pump removal tool 3214 to fuel pump.
- Using tool VAG-3214 turn pump clockwise until notch "C" lines up with mark "B" (see illustration), fuel pump engages.
- Insure that the fuel level sensor is installed in it's original position.