Volkswagen Parts Catalog Volkswagen Accessories Catalog Volkswagen Tech Information Volkswagen Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Bookmark and Share

Pelican Technical Article:

Fuel Pump Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$75 to $200

Talent:

**

Tools:

Large flathead screwdriver, hammer, extraction pump (optional)

Applicable Models:

VW GTI (2006-09)

Parts Required:

Fuel pump, fuel pump sealing O-ring, fuel level sender

Hot Tip:

Work in a well ventilated area

Performance Gain:

Better running engine

Complementary Modification:

Replace fuel filter

The early GTI MkVs are known for having problems with the fuel pump but replacement of the pump is relatively easy. There is an access panel under the rear seat cushion that allows for servicing. To access the pump you will need to first remove the rear seats. 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 the negative battery cable.

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

Disconnect the negative battery cable (yellow arrow) from the battery post (red arrow) and place it somewhere where it cannot come in contact with the post while working on the car.
Figure 1

Disconnect the negative battery cable (yellow arrow) from the battery post (red arrow) and place it somewhere where it cannot come in contact with the post while working on the car.

The fuel pump is located in the right side of the fuel tank.
Figure 2

The fuel pump is located in the right side of the fuel tank. With the seat removed fold back the carpet (yellow arrow) and you will see the access panel to the fuel pump on the right hand side (red arrow).

Pull the wiring connection from the top of the large rubber seal and disconnect the wiring harness (red arrow).
Figure 3

Pull the wiring connection from the top of the large rubber seal and disconnect the wiring harness (red arrow).

Pull the large rubber seal up and out from the sheet metal (red arrow).
Figure 4

Pull the large rubber seal up and out from the sheet metal (red arrow).

Disconnect the wiring from the pump by pulling up on the tab (red arrow) on the connection and removing the connection from the pump (yellow arrow).
Figure 5

Disconnect the wiring from the pump by pulling up on the tab (red arrow) on the connection and removing the connection from the pump (yellow arrow).

Remove the two fuel lines by squeezing in the tabs on the ends of the line connections and pulling them straight up off the pump (red arrows).
Figure 6

Remove the two fuel lines by squeezing in the tabs on the ends of the line connections and pulling them straight up off the pump (red arrows).

Clean the area around the pump and sealing ring.
Figure 7

Clean the area around the pump and sealing ring. There is a special tool that you can buy for torqueing the sealing ring but there is also notches in the ring (red arrow). Take note of where the notches are on the pump before removal and tighten to the same mark when reinstalling. The pump will only fit correctly one way so make sure to note the orientation arrow (yellow arrow) before removing.

Loosen and remove the ring from the top of the pump (red arrow).
Figure 8

Loosen and remove the ring from the top of the pump (red arrow).

Pull the pump and sealing ring from the tank.
Figure 9

Pull the pump and sealing ring from the tank. Make sure to use care when removing the level arm as you have to turn the pump sideways to get it out (red arrow). Always use a new seal between the tank and pump when reinstalling.

In some of the pumps you can replace the fuel level sending unit.
Figure 10

In some of the pumps you can replace the fuel level sending unit. Remove the wires from the unit (yellow arrow) and then the sending unit from the pump (red arrow). Installation is the reverse of removal.

Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Fri 12/9/2016 02:36:11 AM