Suction jet pump, removing and installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

On vehicles with all-wheel drive, the shape of the fuel tank dictates that a suction jet pump unit is required to pump fuel to the fuel delivery unit from the area of the fuel level sensor 2 G169,. The suction jet pump works based on physical principles. It is driven via the fuel supply through an additional fuel pump connection.

NOTE:

A test is only to be performed when the engine shuts off through lack of fuel, even though the fuel level indicator still indicates the fuel tank is filled above the reserve level.

Special tools, testers and auxiliary items required

Fig 1: 3217 Ring Nut Spanner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ring nut wrench 3217

Fig 2: Fuel Siphoning Unit VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel siphoning unit VAS 5190
Torque wrench V.A.G 1332

Requirements

Fuel tank must be drained
Both fuel level sensors must be checked with guided fault finding and be OK: Refer to Electrical Wiring Diagrams, Troubleshooting and Component Locations

Work procedure

Observe safety precautions before performing repair work, refer to Safety precautions when working on fuel supply system .

NOTE:

To perform work sequence, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

With the ignition switched off disconnect battery Ground (GND) strap.
Remove cover under the bench seat.

CAUTION: Fuel system is under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Fig 3: Removing/Installing Union Nut With Wrench 3217

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off 4-pin connector and fuel hoses from fuel delivery unit (right side of vehicle), and remove the fuel delivery unit, refer to Fuel delivery unit, removing and installing .

Fig 4: Removing/Installing Fuel Level Sensor 2 G169 Union Nut On Left Side Of Vehicle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove fuel level sensor 2 G169 union nut on left side of vehicle.
Lift fuel level sensor 2 upward as far as possible.

Fig 5: Separating Cable Ties From Fuel Lines & Spreading Apart The Mount For Suction Jet Pump On Fuel Level Sensor 2

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate cable ties from fuel lines - arrow - and carefully spread apart the mount for suction jet pump on fuel level sensor 2 directional - arrow -.
Unclip and remove suction jet pump with supply and return lines on fuel level sensor 2.
Check that the fuel hoses/lines on suction jet pump are installed securely and are not damaged.
Additionally check suction jet pump for contamination/dirt if necessary.

If no malfunctions are found:

Install suction jet pump and fuel level sensor 2 in reverse order.

If seals are swollen with fuel, always replace.