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.

When removing the connection flange from the fuel pump, the fuel tank should be less than 1/3 full.
- 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.







- Use ring nut spanner 3217 to remove union nut.
- Pull fuel pump and sealing ring out of opening in fuel tank and set aside with lines attached.







- Reach into fuel tank and disconnect harness connector -1-.
- Press release button of hose coupling and disconnect wire -2-.
- Pull retaining strap -3- upward and disengage strap and wire -4- to fuel pump -5-.

NOTE: Fuel pump is shown in removed condition in figure.

- Pull fuel pump and sealing ring out of opening in fuel tank.

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.







- Insert Fuel Pump (FP) -5- in connecting flange of fuel tank (set aside).
- Engage retaining strap -3- of wire -4- to Fuel Pump and press retaining strap into locking mechanism.
- Retaining strap must engage properly







- Press hose coupling of wire -2- together until engagement.
- Connect 2-pin harness connector -1- to fuel level sensor.
- Insert guide of connecting flange into guide of Fuel Pump (FP). Be careful of spring.







- 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.







- Attach 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