Removal and installation of the fuel pump

Note. When removing the electric fuel pump, the fuel tank must be filled no more than 2/3.

Warning! When removing the fuel pump, some fuel may leak out. Fuel vapors are poisonous and flammable, therefore it is necessary to ensure good ventilation of the workplace.

• disconnect the terminal «–» from AB;
• unscrew the filler cap for a short time in order to relieve pressure in the system;
• remove the mat on the right side under the second row of seats, unscrew the mounting bolts and remove the hatch for the electric fuel pump and fuel level sensor;

Pic. 206. Details of the power supply system located near the fuel tank: 1 - fuel tank cap; 2 - sealing ring; 3 - safety ring; 4 - rubber seal; 5 - check valve; 6 - O-shaped sealing ring; 7 - ventilation valve; 8 - pressure reducing valve; 9 - return pipeline; 10 - union nut; 11 - plug, black, pump and fuel quantity sensor; 12 - flange; 13 - supply fuel hose; 14 - sealing ring; 15 - return hose; 16 - check valve; 17 - bolt, 10 Nm; 18 - filler pipe; 19 - ventilation pipeline; 20 - sealing ring; 21 - safety ring; 22 - ventilation pipeline; 23 - bolts, 25 Nm; 24 - fuel tank; 25 - fastening of the fuel tank; 26 - bolts, 20 Nm; 27 - fuel filter cover/holder; 28 - fuel line (black color); 29 - fuel filter (observe the direction of fuel flow); 30 - fuel level sensor in the tank; 31 - fuel pump; 32 - strainer

• disconnect the four-pin connector 11 from the pump (pic. 206) fuel level sensor 30 fuel pump 31;
• disconnect the supply and return 9 pipelines from the flange 12;
• using a special wrench VW 3217, remove the flange 12. If there is no special tool, unscrew the plastic nut, which has small ribs, using a screwdriver (better blunt) hitting her lightly;
• remove flange 12 and sealing ring 14 from the fuel tank opening;

Note. Two fuel lines are connected to the lower side of the flange: supply line 13 (marked with a letter «V») and return (recycling) 15 (marked with a letter «R»).

• turn the fuel pump to the left, moving it out of the bayonet mount, and remove it.

• when installing the pump, do not deform the float of the fuel level sensor in the tank;
• when installing the flange, pay attention to its position. It has an arrow, which, after installation, should be in line with the stamped arrow in the tank;
• moisten the o-ring 14 of the flange with gasoline before assembling;
• check that the supply and return pipes are firmly seated. Secure them with spring clamps.