Fuel Pump: Service and Repair

WARNING: Fuel will be discharged and dangerous fuel vapors will be present. Work in a well ventilated area. Do not disconnect wires that could cause sparks. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.

NOTE: Be sure to have the anti-theft radio code on hand before disconnecting the battery.

REMOVAL
1. Disconnect the negative (-) battery cable.

2. Fold down the rear seat and pull back the floor cover and insulation from the luggage compartment. Remove the access panel from above the fuel pump.




3. Disconnect the harness connector, the supply line, and the return line from the fuel pump.

4. Unscrew the fuel pump retaining ring. Slowly lift the fuel pump assembly from the tank. Empty the fuel pump module into a container once it is removed.

NOTE: VW special tool no. 3217 is available to loosen and tighten the fuel pump retaining ring.

INSTALLATION
1. Inspect the fuel tank seal and replace it if damaged or distorted. Make sure the fuel pump filter screen is clean.

2. Moisten the sealing ring with fuel and install the fuel pump assembly into the tank, using care not to bend the arm for the fuel level float.

NOTE: Align the pump so that the matching mark on the tank aligns with the mark on the pump (see image).

3. Tighten the cap nut.

4. Reconnect the fuel lines and the harness connector.

5. Reconnect the negative (-) battery cable. Start the engine and check for leaks.