Removing, installing and checking suction-jet pump: vehicles with four-wheel drive — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

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• In other work sequences the return supply line must be pulled off junction. When doing this observe that all O-rings must be renewed.
• Use a test hose and blow into connection, from direction of fuel return (2), there must be through flow in directions (3) and (4).
• Hold connections (3) and (4) closed, the pressure relief valve must open under slight opposing pressure.

🔧 Engine codes this applies to

📋 Procedure

1. Read and erase fault memory Fault memory01Reading and erasing fault memory.
2. Note safety precautions before beginning work .
3. ⚠ Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. — First check whether a coded radio is fitted. If so, obtain anti-theft coding.
4. With the ignition switched off, disconnect battery earth strap.
5. Pull 4-pin connector and fuel hoses off fuel delivery unit (right side of vehicle) and remove the fuel delivery unit , removing and installing fuel delivery unit.

6. Now pull 2-pin connector off fuel gauge sender 2G169 (left side of vehicle), open the sealing ring with fuel tank sender unit tool3087 and carefully lift the sender.
7. Now pull off connector (1) under the cover on fuel gauge sender 2 (2).
8. Lift fuel gauge sender 2G169(2) and pull suction-jet pump (3) out of locking device of sender.
9. Take out fuel gauge sender 2G169.
10. Now, on right side of vehicle (fuel delivery unit), pull line to suction-jet pump (2) off junction (1) and pull connector (3) off fuel gauge senderG to fuel gauge sender 2G169.
11. Now the suction-jet pump can be pulled out of the side of fuel gauge sender 2 (left side of vehicle).
12. Check that the fuel lines on suction-jet pump are fitted securely and are not damaged.
13. Additionally check suction-jet pump for possible soiling.
14. Install suction-jet pump and fuel gauge sender 2G169 again in reverse order. [Note: In other work sequences the return supply line must be pulled off junction. When doing this observe that all O-rings must be renewed.]
15. Pull off connections for return supply (2), connections (3) and (4) for suction-jet pump on junction with pressure relief valve (1).
16. Unclip the junction which is secured on the reservoir housing.
17. Use a test hose and blow into connection, from direction of fuel return (2), there must be through flow in directions (3) and (4).
18. Hold connections (3) and (4) closed, the pressure relief valve must open under slight opposing pressure.
19. If no opposing pressure can be determined or the pressure relief valve does not open, renew junction with pressure relief valve.

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