Fuel Pump: Service and Repair

Removing And Installing Fuel Pump

Preliminary work

Preliminary work - Carrera 2
1. Place protective covers on the vehicle.
2. Disconnect and remove battery.







3. Remove carrier plate for battery. Unscrew four M8 hexagon collar nuts -1- and remove lid. Check seal for damage and replace it if necessary.
4. Remove fuel level sensor.
5. Empty the fuel tank.

Preliminary work - Carrera 4
1. Place protective covers on the vehicle.
2. Disconnect the battery.
3. Remove luggage compartment cover.







4. Remove cover for tank flange. Unscrew four M6 cap nuts -2-, remove the four washers and lift off the lid. Check seal for signs of damage.
5. Remove fuel level sensor.
6. Empty the fuel tank until the fuel level is below the pump.

Removing fuel pump

Removing fuel pump - Carrera 2







1. Turn fuel pump anti-clockwise (bayonet lock) and guide it carefully out of the opening of the tank (pay attention to installation position).

Removing fuel pump - Carrera 4







1. Pull off flexible breather hose for the filler neck -1- and plug connection for left fuel line -2-.







2. Release plug connection for fuel line at the right pump -1- and pull off line.
3. Turn fuel pump anti-clockwise (bayonet lock, pay attention to installation position) and tilt slightly towards the front apron.







4. Pull retaining claws of left and right sucking jet pump at the fuel pump -in direction of arrow-.

Installing fuel pump

Installing fuel pump - Carrera 2







1. Fit fuel pump at fuel tank mounting point.







2. Turn fuel pump clockwise as far as it will go.

Installing fuel pump - Carrera 4
1. Insert fuel pump in fuel tank and place it on the floor of the tank for connecting the sucking jet pumps. The connecting grooves must be facing you.







2. Secure sucking jet pumps in the pump using the retaining claws.
3. Fit fuel pump at mounting point and turn it clockwise as far as it will go.
4. Attach line and hose connections to the pump's peripheral equipment.

Subsequent work

Subsequent work - Carrera 2
1. Install fuel level sensor.
2. Install carrier plate for battery. Tighten four hexagon nuts. Tightening torque: 23 (17 ft.lb.) Nm.
3. Install battery.
4. Fill the fuel that you removed back into the tank.
5. Carry out a function test and check the system for leaks.
6. Remove protective covers.

Subsequent work - Carrera 4
1. Install fuel level sensor.
2. Install cover for tank flange. Position and tighten four cap nuts and washers. Tightening torque: 10 (7.5 ft.lb.) Nm.
3. Install luggage compartment cover.
4. Connect ground lead at the battery.
5. Fill the fuel that you removed back into the tank.
6. Carry out a function test and check the system for leaks.
7. Remove protective covers.