Fuel pump (VW Passat B4)

To remove, disconnect the wires from the battery. Lift the luggage compartment carpet and remove the inspection hatch in the body floor. Disconnect the electrical wiring connectors. Mark the fuel supply and drain pipes and disconnect them from the fuel tank. Unscrew the fuel level indicator sensor mounting nut.

Remove the fuel tank assembly.

Remove the fuel pump.

Before installation, clean the fuel line connections and electrical wiring connectors.

Install the fuel pump on the mounting bracket. Install the fuel level indicator sensor assembly with the fuel pump into the fuel tank, screw in and tighten the mounting nut. Install the fuel tank.

Connect the fuel supply and drain lines and connect the electrical connectors. Place the mat on the luggage compartment floor.

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Checking the performance of the fuel pump

Before checking, make sure that the fuel filter is in good technical condition and that there is no damage to the fuel lines.

Disconnect the fuel drain hose from the fuel pressure regulator and lower its free end into the measuring cup. Disconnect the connector from the fuel pump. Turn on the fuel pump for 30 s using an auxiliary current source and measure the amount of fuel poured into the measuring cup, which should be at the voltage at the terminals:

• 9V: 265-285 cm³;
• 10V: 340-360 cm³;
• 12V: 490-510 cm³.

If the performance does not correspond to the specified values, replace the fuel pump.

Connect the fuel pump connector and attach the fuel drain hose to the fuel pressure regulator.