Volkswagen Golf/Jetta 2 manual

Fuel pump - removal and refitting
Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines / Fuel pump - removal and refitting


Removal
1 The fuel pump is located on the underside of the vehicle, forwards of the fuel tank on the right-hand side, the pump being housed in the pump reservoir (see illustrations).

19.1a Fuel pump and associated components
19.1a Fuel pump and associated components

19.1b Fuel pump viewed from rear
19.1b Fuel pump viewed from rear

2 Disconnect the battery earth lead.

3 Raise the vehicle at the rear and support it on axle stands (see УJacking and vehicle supportФ).

4 Prise free the retaining clip and detach the pump wiring connector (see illustration).

19.4 Disconnecting wiring connector from fuel pump
19.4 Disconnecting wiring connector from fuel pump

5 Unscrew the damper unit from the rear end of the pump and detach the hose union, noting the washer each side of the union.

6 Undo the retaining nuts and washers and remove the adapter.

7 Undo the three screws securing the pump retaining ring and withdraw the ring, followed by the pump unit.

8 Remove the O-ring and withdraw the strainer.

Refitting
9 Refitting is a reversal of the removal procedure. Smear the O-ring with fuel when fitting and check that it does not become distorted.

10 When fitting the pump, position it so that its lug engages with the slot in the retaining ring.

11 If the pump non-return valve was removed from the rear end of the pump, refit it using a new seal washer. Also use a new seal washer each side of the hose union. Tighten the damper unit to the specified torque.

12 On completion, start the engine and check for any signs of fuel leakage from the pump connections.


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