Removing, installing and checking suction jet pumps: VW Passat B5 4.0 (BDN, BDP)

🧭 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

📐 6 workshop diagrams for BDN

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid eye injuries and skin contact. Place a cloth over connection before loosening hose clip. Then release pressure by carefully pulling hose off connection. — Switch off ignition and all electrical consumers and remove key.
2. With the ignition switched off, disconnect battery earth strap.
3. Remove fuel delivery unit .
4. Now pull 2-pin connector off fuel gauge sender 2G169 (left side of vehicle), open the sealing ring with key3087 and carefully lift the sender.
5. Now pull off connector (1) under the cover on fuel gauge sender 2G169(2).

6. Lift fuel gauge sender 2G169(2) and pull suction jet pump (3) out of locking device of sender.
7. Take out fuel gauge sender 2G169.
8. Now, on right side of vehicle (fuel delivery unit), pull hose/pipe to suction jet pump (2) off junction (1) and pull connector (3) off fuel gauge senderG to fuel gauge sender 2G169.
9. Now the suction jet pump can be pulled out from side of fuel gauge sender 2G169 (left side of vehicle).
10. Check that the fuel lines on suction-jet pump are fitted securely and are not damaged.
11. Additionally check suction-jet pump for possible soiling.
12. 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.]
13. Pull off connections for return supply (2), connections (3) and (4) for suction-jet pump on junction with pressure relief valve (1).
14. Unclip the junction which is secured on the reservoir housing.
15. Use a test hose and blow into connection, from direction of fuel return (2), there must be through flow in directions (3) and (4).
16. Hold connections (3) and (4) closed, the pressure relief valve must open under slight opposing pressure.
17. 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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