Fuel Pump Assembly 1992

[KennyBucket]

Can anyone provide me with instructions to replace a fuel pump assembly(pump, filter, tank)? Thanks

[passatGLwgn]

Originally Posted by KennyBucket

Can anyone provide me with instructions to replace a fuel pump assembly(pump, filter, tank)? Thanks

Pull your pumps fuse.Its the # 18, 20 amp.Pull it.Run the thing until it won't start at all.That will remove some of the pressure, if any in the system.NO SMOKING under there! Use a good quality pump (NASCAR styled) floor jack.Get it up enough you can lie under the vehicle.Before venturing under it, use supportive frame jacks to support the entire rear half.Block the fronts.Now, using 13mm deep socket, remove the cover nuts.Mine looked like they would shear off, but they lasted another change out. Now, look at the assembly.The 19mm banjo bolts on the pump delivery to the filter are often really rusted.However,Mine were'nt. Anyway, I did'nt hurt them.If you can get a big Pump plier, or a large channel lock on the pump, you'll be able to turn out the 2 banjoed 19's.
Might as well refilter the car too.Its easy. The lines are whats often the worse shape.I broke my 19mm-to-17mm banjo line.Aeroquip--luckily, is located in my city, they carry an assortment of pressure lines, banjo bolts, and brass washers. The retourqed values are 15nm.ALWAYS replace the washers, if not the bolts.I needed just the new washers.The pump is concealed in a plastic resevoir box.The ins and outs are easily sorted once you see the top of the box.The pump only goes in one way, electrics facing the rear.Easy does it on that connector.I used extra caution.Once out, another 2 quarts of fuel will want to pour out.Use a catch can.I plugged mine with corks. Once you see the assembly on the bench, you will figure it out.The GIANT O-ring only fits one way, or you will see a massive leak. Nope...they arent at all like the oldies.The Rabbit design was awesome.Everything was right where a guy could do it.They reloacted the filter to safer location in case of tramatic fire occurring.That things under immense pressure, so the front mounting of it was shoved to the rear...(a better escape if in a fiery accident I guess) Good luck...So simple, A monkey can do it. It just looks hard.