Fuel Pump: Service and Repair

Removal
1. Undo battery terminals and battery holder. Lift battery out by holding strap.
2. Undo battery support cover (four hexagon nuts, wrench size 13).
3. Disengage fuel line and disconnect electrical plug connection.







4. Undo union nut with VW special tool 3217.







5. Extract residual fuel.


NOTE: Observe safety regulations.


6. Lift fuel gauge and disconnect electrical plug connection and fuel pipes.







7. Put on fuel-proof glove, hold the fuel pump fastened to tank floor, turn it to left (approx. 15°, bayonet lock) and remove fuel pump.

Installation
1. Position fuel pump; the edge of the fuel-pump housing faces the fuel tank sending unit installation-position markings.







2. Place fuel pump in this position on tank floor bayonet fixture and turn fuel pump to the right as far as the stop. Then check proper seating of fuel pump by pulling it up.
3. Insert fuel tank sending unit and turn until the marking on the sending unit matches the marking on the fuel tank.







4. Tighten union nut with special tool 3217. Tightening torque with new union nut and new sealing ring: 70 Nm (52 ft. lbs.).
5. Attach fuel lines and electrical plug connection. The fuel lines must audibly engage.
Correct engagement must be checked with a gentle pull.
The colour-coded plug (green) must be fitted to the connection identified with "V".