Removing and Installing Fuel Pump

Removing And Installing Fuel Pump

Technical values







Preliminary work

Preliminary work - Carrera 2
1. Place protective covers on the vehicle.
2. Disconnect and remove the battery.







3. Remove carrier plate for battery. Unscrew four M8 hexagon collar nuts -1- and remove the cover.
Check seal for damage and replace it if necessary.
4. Remove fuel level sensor.
5. Drain the fuel tank.

Preliminary work - Carrera 4
1. Place protective covers on the vehicle.
2. Disconnect the battery.
3. Remove luggage compartment cover.







4. Remove cover for tank flange.
Unscrew four M6 cap nuts -2-, remove the four washers and lift off the cover. Check seal for signs of damage.

5. Remove fuel level sensor.
6. Drain the fuel tank until the fuel level is lower than the pump.

Removing fuel pump

Removing fuel pump - Carrera 2







1. Turn fuel pump anti-clockwise (bayonet lock) and guide it carefully out of the opening of the tank (pay attention to installation position).

Removing fuel pump - Carrera 4







1. Disconnect the fuel pump.
1.1. Pull off flexible breather hose for the filler neck -1- and plug connection for the fuel line -2- on the left.







1.2. Loosen plug connection for the fuel line at the fuel pump -1- on the right and pull off the line.

2. Remove the fuel pump.
2.1. Turn the fuel pump anti-clockwise (bayonet lock, note installation position.) and tip it slightly towards the front end.







2.2. Pull the retaining claws on the left and right sucking jet pump at the fuel pump -in direction of arrow-.

Installing fuel pump

Installing fuel pump - Carrera 2







1. Install fuel pump.
1.1. Fit the fuel pump into the fuel tank mounting.







1.2. Turn the fuel pump clockwise as far as it will go.

Installing fuel pump - Carrera 4
1. Install fuel pump.
1.1. Guide the fuel pump into the fuel tank and set it down on the floor of the tank in order to connect the sucking jet pumps.







1.2. Secure the sucking jet pumps using the retaining claws in the fuel pump.
1.3. Insert the fuel pump into the mounting and turn it clockwise as far as it will go.
1.4. Connect line and hose connections to the fuel pump.

Subsequent work

Subsequent work - Carrera 2
Connecting sucking jet pumps to pump
1. Install fuel level sensor.
2. Install carrier plate for battery. Tighten four M8 hexagon collar nuts.
Tightening torque: 23 Nm (17 ftlb.).
3. Install the battery.
4. Fill fuel that was removed back into the fuel tank.
5. Carry out a function test and check the system for leaks.
6. Remove protective covers.

Subsequent work - Carrera 4
1. Install fuel level sensor.
2. Install cover for tank flange. Fit and tighten four M6 cap nuts and washers.
Tightening torque: 10 Nm (7.5 ftlb.)
3. Install luggage compartment cover.
4. Connect ground lead to battery.
5. Fill fuel that was removed back into the fuel tank.
6. Carry out a function test and check the system for leaks.
7. Remove protective covers.