Auxiliary Fuel Pump -V393- (IN-LINE ELECTRIC FUEL PUMP)

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque Wrench (5-50 Nm) V.A.G 1331
Hose Clip Pliers VAS 6362

CAUTION:

Observe the safety precautions when working on the fuel supply system. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

Removing

-- Disconnect the connector -2- from the exhaust pressure sensor 1 -G450- -1-.

Fig 1: Identifying Exhaust Pressure Sensor -1-, Connector -2-, Bolt -4- And Bracket -3-

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-- Remove the bolt -4- and bracket -3- with the exhaust pressure sensor 1 -1- in the -direction of the arrow- and lay them aside (the control wires remain connected).

-- Disconnect the connector -1- from the auxiliary fuel pump.

Fig 2: Identifying Connector -1- To Auxiliary Fuel Pump And Fuel Hoses -2 / 3-

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-- Unclip the fuel hoses -2 and 3- from the bracket.

-- Loosen the hose clamp using hose clip pliers VAS 6362 and remove the fuel supply line -item 6- from the fuel filter, refer to: FUEL FILTER OVERVIEW .

-- Disconnect the connector from the fuel temperature sensor -G81- -arrow-.

Fig 3: Identifying Spring Clamp -1- And Fuel Temperature Sensor -G81- -Arrow-

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-- Loosen the spring clamp -1- using hose clip pliers VAS 6362 and remove the fuel supply line from the high pressure fuel pump.

-- Seal the lines so that the fuel system is not contaminated by dirt, etc.

-- Remove the bolts -arrows- and the auxiliary fuel pump.

Fig 4: Identifying Bolts To Auxiliary Fuel Pump

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Installing

Install in reverse order of removal. When doing this note the following:

Route the fuel hoses free of kinks.
Ensure fuel hoses are seated securely.
Do not interchange the supply and return lines (the return line is blue or has a blue mark, the supply line is white or has a white mark).
Clip the fuel and coolant hoses back into the retainers.

Tightening Specifications

Bolt for the exhaust pressure sensor 1 bracket, 8 Nm.
Auxiliary fuel pump bolts, 20 Nm.

-- Fill and bleed the fuel system. Refer to FUEL SYSTEM, FILLING AND BLEEDING .