Fuel Pump, Removing and Installing

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

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