Fuel Pump (FP) unit, removing and installing

WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen R32, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Recommended special tools and equipment

Fig 1: 3217 Ring Nut Spanner

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3217 ring nut wrench

Fig 2: Torque Wrench V.A.G. 1332 (40 To 200 Nm)

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V.A.G 1332 torque wrench (40 to 200 Nm)

Requirements

Parking brake must be engaged or else daylight driving lights will be switched on.
Ignition switched off.
Fuel tank must be empty. Refer to Fuel tank, draining , emptying fuel tank.

Removing

Observe safety precautions. Refer to Safety precautions when working on fuel supply system .

Observe rules for cleanliness. Refer to Rules of cleanliness .

First determine whether a coded radio is installed. In this case, determine the anti-theft coding.
Switch ignition off and disconnect Battery Ground (GND) strap.
Fold rear seatback forward.
Remove cover from Fuel Pump (FP) unit

Fig 3: Fuel Delivery Unit Connector & Supply And Return Lines

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Disconnect 4-pin harness connector as well as supply and return lines from flange (arrows).

NOTE: Depress buttons on hose connections to do so.

WARNING:

The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Wear protective goggles and protective gloves when working on the fuel system!

Seal off lines so that no dirt will get into fuel system.

Fig 4: Removing/Installing Union Nut With Wrench 3217

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Use 3217 ring nut wrench to remove union nut.

Vehicles with engine code BJS

Fig 5: Identifying Supply Line Hose Connection To Suction Jet Pump & 2-Pin Connection

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Disconnect 2-pin harness connector -1-.
Disconnect supply line -2- from suction jet pump at fuel pump.

NOTE: Depress buttons on hose connections to do so.

Fig 6: Lifting The Fuel Delivery Unit Slightly And Pulling Bracket With Return Line

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Lift Fuel Pump (FP) unit slightly and pull bracket with return line -arrow- upward and off.

Continuation for all vehicles

Pull Fuel Pump (FP) unit and sealing ring from opening of fuel tank

NOTE: When replacing Fuel Pump (FP) unit, empty old Fuel Pump (FP) unit before disposing.

Installing

Installation of the Fuel Pump (FP) unit is the reverse order of removal.

NOTE:

Always replace seals if they are swelled up due to fuel.
Insert dry flange seal of fuel pump into opening of fuel tank.
Only coat seal with fuel when installing Fuel Pump (FP) unit.
When inserting Fuel Pump (FP), be sure not to bend sender for fuel gauge.
Note installation position of Fuel Pump (FP) unit flange:

Marking on flange must align with marking on fuel tank (arrows).

Fig 7: Installed Position Of Flange Of Fuel Delivery Unit

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NOTE:

Make sure fuel lines are securely fastened.
After installing Fuel Pump (FP) unit, check whether supply, return and ventilation lines are still clipped in at fuel tank.

Erase DTC memory of Engine Control Module (ECM). Refer to Diagnostic mode 4: Reset/erase diagnostic data
Generate readiness code. Refer to Readiness code, generating