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DIY intank fuel pump removal

flipkid

Passed Driver's Ed
Location
Las Vegas
I just replaced my in tank fuel pump. I tried finding a DIY for a MKV but only found a MKIV by dremhmrk2 from vwvortex .

I used some of his DIY to make this.

1. Pull fuse for low pressure fuel pump (in-tank fuel sender)


2. Remove bottom portion of back seat (Use NewaveRide DIY http://www.golfmkv.com/forums/showthread.php?p=902339)


3. Lift up passenger side carpet to expose access panel


4. Remove wiring module


5. Unplug harness from module


6. Start car and let engine run until it cuts out

7. Pry up wiring boot from access panel


8. Lift off access panel




9. Disconnect wiring harness from fuel pump


10. Using flat head screw driver, pry up slightly at these points on retaining ring


11. Use a rubber mallet and flat head to spin retaining ring counter-clockwise

12. Having rags handy, unclip the hoses (by pressing on the side of the D-clip) and pull off slowly (there will be built up pressure left in the pump, gas will come out)


13. Remove sending unit and gasket (be aware of the fuel level float attached to the pump)

When installing new fuel pump you have to pinch the points back down on retaining ring referred to on step 10 before spinning retaining ring clockwise to lock fuel pump in place.


Thanks for reading. Please post any other tips and tricks to this DIY.
 
Last edited:

stringshifter6

Nom Nom Nom
Location
Burbank, CA
Ride
2007 GTI
So has this resolved the problem? I got the same nasty fuel cut during a drive to Vegas in the heat.

You don't happen to have the part numbers for the updated pump do you?
 

stringshifter6

Nom Nom Nom
Location
Burbank, CA
Ride
2007 GTI
1-k0-919-051-BH This part number was given in another thread regarding the low pressure fuel pump. Is the -cl suffix another revision?
There is a 60 dollar difference between the two but looking up the -bh suffix does not reveal any part superseding it.
 

bostonaudi

New member
Location
Charleston, SC
Ride
1995 BMW M3
Update - pump is now 1K0 919 051 DB.

Also, have a turkey baster and a pail on hand to do this so you can empty the pump basin before you pull it out.
 

haithame

Apple GTI
Location
Earth
Ride
'09 GTI MKV
Update - pump is now 1K0 919 051 DB.
Yes, this is the new revision. The dealer installed that new revision for me today.

I was having these cuts during hot weather long driving. Not sure whats new in the new revision though.

I am also facing a weird issue. I did hard acceleration from stop today and suddenly I had ABS, EPS & Hand Brake lights all on. After turning off the car and on again, all these lights are gone.
When I discussed this with the dealer, they told me that this issue might be related to the pump issue!!
 

Nightdeath4223

New member
Location
Keller, TX
Ride
GTI
Well I am stuck on getting the ring to loosen up. Since there really is no way for me to see what clips that are to be peeled back. Right now the ring is just on there super tight. Any suggestions?
 

bostonaudi

New member
Location
Charleston, SC
Ride
1995 BMW M3
Flat head and a hammer.
In a pinch, that works, but you don't know whether its tight enough - if it isn't, fuel will seep. Try to find someone local who has the T10202 tool and make sure its torqued to 80 ft-lb. The tool is about $45.



You can see on the bottom how it hooks the ring.

 

foolishfreeheel

New member
Location
United States
Yeah. I had fuel cuts when driving for a long time in the heat. Also had to change out the fuel pressure sensor attached to the hpfp.
Did you remember what your CEL codes were?
I've had a similar situation happen at high speeds in hot weather and brief fuel cut occurs. The CEL came on then then disappeared the next day. The code was P2293 and from previous research leads me to believe it is the cam fallower.

Any thoughts?
'06 GTI DSG 55k miles
 
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