Fuel Pump: Service and Repair

Fuel pump, removing and installing

Special tools and equipment



Ring nut spanner 3217

Removing

- Observe safety precautions.
- Observe rules for cleanliness.

WARNING! Fuel tank must be less than 1/3 full when removing fuel pump. If necessary,empty fuel tank.

Note radio code (for vehicles with coded anti-theft radio). Obtain if necessary.

Vehicles with 4-cylinder engine




- If installed, remove cover above battery.
- Open battery protective casing (Velcro).



- Switch ignition off and disconnect battery Ground (GND) strap (arrow).

Vehicles with 6-cylinder engine




- Switch ignition off and disconnect battery Ground (GND) strap (arrow) under trunk floor.

TT Coupe
- Remove rear seat bench.

TT Roadster
- Remove rear panel side trim.

Continued for all vehicles




- Unscrew cover -1- at right (arrows).



- Disengage 4-pin electrical harness connector and remove (arrow).

WARNING! Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.




- Disconnect fuel supply line -1- and fuel return line -2- (press release button).

WARNING! Fuel tank must be less than 1/3 full when removing fuel pump. If necessary,empty fuel tank.




- Use ring nut spanner 3217 to remove union nut.
- Pull fuel pump and sealing ring from opening of fuel tank.

Note: If Fuel Pump (FP) is still full of fuel, empty fuel before replacing.

Installing

Installation is the reverse of removal, noting the following:

Note:
- Insert new, dry seal for connection flange into opening of fuel container.

- When inserting Fuel Pump (FP) into fuel tank, be sure not to bend fuel level sensor.

- Make sure fuel hose is securely fastened.




- Press connecting flange down against spring pressure and bring connecting flange into proper installation position.
- Marking on connecting flange must align with marking on fuel tank (arrows).
- Apply union nut by hand.



- Use ring nut spanner 3217 to tighten union nut (80 Nm).



- Connect fuel lines.
- Black supply line -1- to connection with identification -V-.
- Blue return line -2- to connection with identification -R-.
- Connect 4-pin harness connector.

Note:
- After connecting battery, be sure to activate the electrical accessories (radio, clock, power windows).

- Additional precautions for reconnecting the power supply:

- Generate readiness code.

Tightening torques
Union nut for Fuel Pump (FP) 80 Nm
Battery terminal to battery post 5 Nm