HOW TO REMOVE AN ELECTRIC FUEL PUMP FROM A VOLKSWAGEN PASSAT
Applies To: VW PASSAT (1998-2005)
Recommended Tools
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Flathead Screwdriver
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Phillips Head Screwdriver
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Wire Cutters
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Pliers
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Safety Glasses
Instructions
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1
VW has a special tools for removing the pump ring, and to release the pump from the bottom of the fuel tank releasing the pump from the bottom of the tank. The job can be done without these special tools
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2
The fuel pump is located in the luggage compartment and there might be a luggage cover that is over it, if there is then remove the cover
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3
Remove the three Phillips head screws on the fuel pump cover
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4
Then remove the connector and the rubber piece and get them out of the way
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5
Take the lines off by cutting the two clamps
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6
Use a flathead screwdriver and push the clamp off
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7
Be careful not to damage the lines or your hand. If you are having trouble removing the fuel lines from the fuel pump, use a pair of pliers and give the lines a light squeeze and twist
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8
Use the flat head screwdriver to work the line off. Once the lines are off, make sure to tuck them out of the way
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9
Use a flat head screwdriver to tap off the plastic collar. Start tapping in a counterclockwise direction until the collar comes complete off (Do not hit directly down on the collar, instead hit at an angle that is more rounded)
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10
The fuel pump is two pieces: one part is at the top of the tank and the other is mounted at the bottom of the tank
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11
First use a flat head screwdriver to take off the top part of the fuel pump. Pull the top portion up and remove the seal
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12
Disconnect the electical connector and the vent from the top and of the fuel pump. Remove the lower section of the fuel pump all you will need to do is turn it counterclockwise
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13
The pump will only turn 10° and you will be able to wiggle the fuel pump out
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14
VW has a special tools for removing the pump ring, and to release the pump from the bottom of the fuel tank releasing the pump from the bottom of the tank. The job can be done without these special tools
-
15
The fuel pump is located in the luggage compartment and there might be a luggage cover that is over it, if there is then remove the cover
-
16
Remove the three Phillips head screws on the fuel pump cover
-
17
Then remove the connector and the rubber piece and get them out of the way
-
18
Take the lines off by cutting the two clamps
-
19
Use a flathead screwdriver and push the clamp off
-
20
Be careful not to damage the lines or your hand. If you are having trouble removing the fuel lines from the fuel pump, use a pair of pliers and give the lines a light squeeze and twist
-
21
Use the flat head screwdriver to work the line off. Once the lines are off, make sure to tuck them out of the way
-
22
Use a flat head screwdriver to tap off the plastic collar. Start tapping in a counterclockwise direction until the collar comes complete off (Do not hit directly down on the collar, instead hit at an angle that is more rounded)
-
23
The fuel pump is two pieces: one part is at the top of the tank and the other is mounted at the bottom of the tank
-
24
First use a flat head screwdriver to take off the top part of the fuel pump. Pull the top portion up and remove the seal
-
25
Disconnect the electical connector and the vent from the top and of the fuel pump. Remove the lower section of the fuel pump all you will need to do is turn it counterclockwise
-
26
The pump will only turn 10° and you will be able to wiggle the fuel pump out