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Home >> Volkswagen >> 2001 >> Jetta GL, 2.0 B >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 46 (2.8L & 3.2L - Generic Scan Tool, Engine Code(S): AFP, BDF, BJS [A4 Platform] (20 Fuel Supply - 26 Exhaust System, Emission Controls)) >> 20 Fuel Supply >> Fuel supply system components, removing and installing >> Fuel Pump (FP) unit, removing and installing

Fuel Pump (FP) unit, removing and installing

WARNING: This page is about a different variant/trim than selected.

Recommended special tools and equipment 

Fig 1: 3217 Ring Nut Spanner
GW00000170Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 2: Torque Wrench V.A.G. 1332 (40 To 200 Nm)
GW00000114Courtesy of VOLKSWAGEN UNITED STATES, INC.

Requirements 

Removing 

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

Observe rules for cleanliness. Refer to Rules of cleanliness  .

Fig 3: Fuel Delivery Unit Connector & Supply And Return Lines
GW00000171Courtesy of VOLKSWAGEN UNITED STATES, INC.
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!
Fig 4: Removing/Installing Union Nut With Wrench 3217
GW00000172Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with engine code BJS 

Fig 5: Identifying Supply Line Hose Connection To Suction Jet Pump & 2-Pin Connection
GW00000537Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE: Depress buttons on hose connections to do so.
Fig 6: Lifting The Fuel Delivery Unit Slightly And Pulling Bracket With Return Line
GW00000538Courtesy of VOLKSWAGEN UNITED STATES, INC.

Continuation for all vehicles 

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

Installing 

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
GW00000163Courtesy of VOLKSWAGEN UNITED STATES, INC.
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.
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