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Pelican Technical Article:

Fuel Pump Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$150 to $175

Talent:

**

Tools:

Philips head screwdriver, large claw type wrench, extraction pump (optional)

Applicable Models:

VW Golf GTI (1999-00)
VW Golf GTI 1.8T (2002-05)
VW Golf GTI 20th Anniversary (2003)
VW Golf GTI 337 (2002)
VW Golf GTI GLS (2001)
VW Golf GTI GLX (2000-01)
VW Golf GTI VR6 (2002-05)

Parts Required:

Fuel pump, fuel pump sealing O-ring

Hot Tip:

Work in a well ventilated area

Performance Gain:

Better running engine

Complementary Modification:

Replace fuel filter

Replacing the fuel pump on a Volkswagen GTI MkIV can be done without removing the fuel tank. There is an access panel under the rear seat cushion that allows servicing. To access the pump you will need to first remove the rear seat. Please see our article on removing your seats. A faulty fuel pump can cause poor engine performance and hard starting problems. When they fail completely, you may be left with an engine that doesn't run at all.

It is best to replace your fuel pump with the fuel tank drained. This reduces the amount of possible spilled fuel and fuel vapors. When replacing, work in a well ventilated area, working outdoors is a good choice. Do not use incandescent work lights or power tools and DO NOT smoke, fuel and fuel vapors are highly combustible.

Disconnect negative battery cable.

Remove fuel cap, then slide an anti-static siphon hose down fuel filler neck. Once hose has bottomed out, pump fuel out of fuel tank into an approved storage container. You can refill the tank with this fuel when the job is complete.

The fuel pump is located in the right side of the fuel tank.
Figure 1

The fuel pump is located in the right side of the fuel tank. With the seat removed you will see the access panel to the fuel pump on the right hand side (red arrow). The carpet in our project car was going to interfere removing the access panel (yellow arrow) so I cut it back to give myself more room to work.

Remove the three Philips head screws (red arrows) holding it in place and gently pry the panel up.
Figure 2

Remove the three Philips head screws (red arrows) holding it in place and gently pry the panel up. There is a small sticky gasket between the panel and the body of the car to help reduce noise and vibration so do not clean that off.

With the access panel off you can see the locating cover and ring seal on the pump.
Figure 3

With the access panel off you can see the locating cover and ring seal on the pump. There are two fuel lines; one supply (Green arrow) and the return line (red arrow) along with a electrical harness connecter (yellow arrow).

Remove the electrical connecter (yellow arrow).
Figure 4

Remove the electrical connecter (yellow arrow).

Remove the fuel supply line (green arrow) and the fuel return line (yellow arrow).
Figure 5

Remove the fuel supply line (green arrow) and the fuel return line (yellow arrow).

The unit needs to sit in the tank in a specific orientation.
Figure 6

The unit needs to sit in the tank in a specific orientation. Make sure you note the witness arrows on the unit (yellow and green arrows) and make sure the new unit sits in the same manner.

Use a large claw type wrench (red arrow) and remove the ring seal.
Figure 7

Use a large claw type wrench (red arrow) and remove the ring seal. It is on tight and if you try and unscrew it by tapping the plastic notches with a flat head screw driver you will just shear off the notches.

Grasp the pump (yellow arrow) and remove it from the tank.
Figure 8

Grasp the pump (yellow arrow) and remove it from the tank.. Inspect the seal (green arrow) and replace if necessary.

Take care not to bend the fuel gauge sending unit arm (yellow arrow) when removing or reinstalling the unit.
Figure 9

Take care not to bend the fuel gauge sending unit arm (yellow arrow) when removing or reinstalling the unit. Installation is the reverse of removal

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Page last updated: Wed 12/7/2016 02:36:01 AM