Fuel Pump: Service and Repair
WM 206619 Removing and installing fuel pump
Technical values
Preliminary work
Preliminary work - Carrera 2
1. Place protective covers on the vehicle.
2. Disconnect and remove the battery.
-> 270619 Removing and installing battery - section on "Removing" 27061900 Removing and installing battery
3. Remove carrier plate for battery.
Carrier plate for battery
Unscrew four M8 hexagon collar nuts -1- and remove the cover. Check seal for damage and replace it if necessary.
4. Remove fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Removing" Service and Repair
5. Drain the fuel tank.
-> 2010EN Draining and filling the fuel tank - section on "Draining" Procedures.
Preliminary work - Carrera 4
1. Place protective covers on the vehicle.
2. Disconnect the battery.
-> 2706IN Work instructions after disconnecting the battery
3. Remove luggage compartment cover.
-> 700519 Removing and installing front luggage compartment trim panel - section on "Removing"
4. Remove cover for tank flange.
Cover for tank flange
Unscrew four M6 cap nuts -2- , remove the four washers and lift off the cover. Check seal for signs of damage.
5. Remove fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Removing" Service and Repair
6. Drain the fuel tank until the fuel level is lower than the pump.
-> 2010EN Draining and filling the fuel tank - section on "Draining" Procedures
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).
Fuel pump C2
Removing fuel pump - Carrera 4
1. Disconnect the fuel pump.
Connections for left fuel pump
1.1. Pull off flexible breather hose for the filler neck -1- and plug connection for the fuel line -2- on the left.
1.2. Loosen plug connection for the fuel line at the fuel pump -1- on the right and pull off the line.
Connection for fuel line on the right
2. Remove the fuel pump.
2.1. Turn the fuel pump anti-clockwise (bayonet lock, note installation position!) and tip it slightly towards the front end.
2.2. Pull the retaining claws on the left and right sucking jet pump at the fuel pump -in direction of arrow-.
Connection for sucking jet pumps
Installing fuel pump
Installing fuel pump - Carrera 2
1. Install fuel pump.
Installing fuel pump
1.1. Fit the fuel pump into the fuel tank mounting.
1.2. Turn the fuel pump clockwise as far as it will go.
Fuel pump C2
Installing fuel pump - Carrera 4
1. Install fuel pump.
1.1. Guide the fuel pump into the fuel tank and set it down on the floor of the tank in order to connect the sucking jet pumps.
1.2. Secure the sucking jet pumps using the retaining claws in the fuel pump.
Connecting sucking jet pumps to pump
1.3. Insert the fuel pump into the mounting and turn it clockwise as far as it will go.
1.4. Connect line and hose connections to the fuel pump.
Subsequent work
Subsequent work - Carrera 2
1. Install fuel level sensor.
-> 201519 Removing and installing fuel level sensor - section on "Installing" Service and Repair
2. Install carrier plate for battery. Tighten four M8 hexagon collar nuts.
=> Tightening torque: 23 Nm (17 ftlb.).
3. Install the battery.
-> 270619 Removing and installing battery - section on "Installing" 27061900 Removing and installing battery.
4. Fill fuel that was removed back into the fuel tank.
-> 2010EN Draining and filling the fuel tank - section on "Filling" Procedures.
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.
-> 201519 Removing and installing fuel level sensor - section on "Installing" Service and Repair
2. Install cover for tank flange. Fit and tighten four M6 cap nuts and washers.
=> Tightening torque: 10 Nm (7.5 ftlb.).
3. Install luggage compartment cover.
-> 700519 Removing and installing front luggage compartment trim panel - section on "Installing"
4. Connect ground lead to battery.
-> 2706IN Work instructions after disconnecting the battery
5. Fill fuel that was removed back into the fuel tank.
-> 2010EN Draining and filling the fuel tank - section on "Filling" Procedures
6. Carry out a function test and check the system for leaks.
7. Remove protective covers.