Fuel Pump Module, Removing and Installing
- Observe safety precautions.
- Observe rules of cleanliness.
Special tools, test equipment and auxiliary items
- VAG 1433A fuel cart or other approved equivalent
- 3087 wrench for sender for fuel gauge
- 3307 fuel pump wrench
Removing
- Pull rubber gasket off toward front (arrow).
- Remove plenum chamber cover -1- toward front.
- Disconnect battery Ground (GND) strap (arrow).
CAUTION! Before disconnecting the battery, determine the correct coding for the anti-theft radio.
NOTES:
- The fuel tank must not be more than 1/4 full.
- If necessary, empty the fuel tank using VAG 1433A fuel cart or similar approved equipment.
- Under right-rear seat bench, remove cover for closing flange.
WARNING!
- Fire Hazard. Do not smoke, work near heaters or have anything in the area that could ignite the fuel or fumes.
- Fuel supply lines are under pressure! Before loosening any lines, cover the connection with a rag. Release the pressure by slowly separating the connection.
- Mark fuel pressure line -1- and return line -2- and disconnect from closing flange.
- Carefully release 4-pin harness connector and disconnect.
- Remove closing ring for sender for fuel gauge using 3087 wrench.
- Remove closing flange and seal from fuel tank opening.
- On inside of closing flange, remove both harness connectors to fuel gauge.
- Disengage distributor connector -1- at lower part of accumulator by pressing distributor connector slightly to left side of vehicle and lift upward (arrow).
- Release return line -2- from distributor connector and disconnect.
NOTE: To better show the distributor connector the fuel tank is not shown in the illustration.
- Insert 3307 fuel pump wrench through fuel tank opening into inner part of accumulator.
- Using 3307 wrench, turn inner part of accumulator approx. 15° toward left (to stop) and lift out fuel pump together with inner part of accumulator.
NOTE: If replacing the fuel pump module make sure to drain the old unit.
Installing
Installation is the reverse of removal, however note the following:
NOTE: Replacement hose clamps must be the same type of clamp that was used in production See parts catalog microfiche.
- Install fuel pump module into tank with notch -1- on fuel pump module lining up with marking -2-on outside of fuel pump module.
It should feel that it is possible to press fuel pump module down.
- Using 3307 fuel pump wrench, turn fuel pump module approx. 15° to right (to stop). Notch -1- must then align with marking -3-.
NOTE: To better show the procedure, the accumulator housing is shown without the fuel tank.
- Push return line -2- Onto distributor connector -1- until hose coupling engages.
- Insert distributor connector into lower part of accumulator until tabs -3- engage.
- Reconnect harness connectors for fuel gauge to inside of closing flange.
- Make sure hoses and wiring are routed properly.
- When installing, turn closing flange in direction of arrow.
NOTE: When installing, moisten the flange seal with fuel and install into the fuel tank opening.
- Install closing flange into tank opening. Note installation position:
- Marking on closing flange (arrow -1-) must align with marking (arrow -2-) on fuel tank.
NOTE: The black arrow points toward the front of the vehicle.
- Tighten closing ring.
- Install fuel supply and return lines as previously marked.
- Install cover for closing flange with indentation over connector.
- With ignition switched off, reconnect battery Ground (GND) strap.
NOTE: Carefully install the cover for plenum chamber under the wind shield to prevent water from entering the pollen filter or the heater
- With ignition switched off, reconnect battery Ground (GND) strap.
- After reconnecting battery, insert radio code.
- Using switches, fully close power windows up to stop.
- Operate all power windows for at least 1 second in "close" position to activate "one touch" opening/closing feature.
- Set time display on clock.