Question about 2003 Volkswagen Jetta TDI

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Fuel pump on 2001 Jetta 1.8 doesn't pressurize to start. Checked fuse -- OK. Plan to check relay next -- how do I do this? If, as I presume, the pump itself is the problem (making noise last few days), how do I replace the pump itself? thanks, clint

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  • clintreece Nov 13, 2010

    Thanks,
    I'm trying to confirm that the problem is the pump itself and not the relay (I've checked the fuse already).
    When I have someone open the driver's door while I listen at the filler door, I can hear intermittent "gurgling" from within the fuel tank.
    When the key is turned to the 'on' position, the same noises are heard from the fuel tank filler, but I don't hear a 'click' from the relay under the steering column.
    I plan to get access to the wiring on the fuel pump and check for power there -- make sense?

  • clintreece Nov 13, 2010

    Am at the fuel pump -- any tips for removing the wiring clip?

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Hello
The fuel pump is part of a fuel pump module Assembly located inside the fuel tank, this is the problem you have, so you will need to replace the fuel pump module Assembly, see picture below.

Here are the instructions to replace the pump, remember there is a fire hazard here, also when done and testing remember the pump only runs for one second unless the engine is cranking or started..

The fuel pump Module is accessible through the trunk floor, pull the trunk liner out, then remove the 3 screws that are on the black cover on the passenger side of the trunk floor. The first thing I would do at this point would be to check the wiring connector to the fuel pump and sender, make sure the connector shell isn't burnt looking or the wires discolored from heat, if you find this contact your local VW dealer for a repair connector. There are 4 wires in the plug there. The 2 SMALLER wires are for the fuel gauge, the other 2 BIG wires are for the fuel pump. at this point make sure the brown wire is a good ground to the pump (the brown wire) for resistance to the body, it should be less than three ohms, now remove the two fuel lines and vent hose (this may require a special tool to release fuel lines, you can buy that from any Napa or Carquest parts store, to release the fuel pump lock ring move it clockwise, lift the fuel pump module up and out, keep a rag handy to soak up fuel, put everything back together in reverse order.

Posted on Nov 13, 2010

  • yadayada
    yadayada Nov 13, 2010

    Here is the picture of the fuel pump module assembly




  • yadayada
    yadayada Nov 13, 2010

    The fuel pump connector just snaps off, the wire clip is a spring retainer same as all Bosch design connectors, sometimes a small pocket screwdriver can be used to snap them free, you can also remove the clip, pry out on the end. To check power to the pump probe the wiring connector with a 12 volt test light (available from any auto parts store) while someone cycles the key on and off, you should get battery voltage for one second at one of the larger wires that feed the fuel pump power.

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