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DIY Fuel Pump Replacement w/fuel filter assy.

50K views 25 replies 14 participants last post by  ingemarstewart  
#1 ·
this is a non mechanic version on how to change the fuel pumps and also insight on some of the fuel systems major components.

DEALER WANTED 2500 TO DO THIS JOB. I SAID F YOU PAY ME:cool::cool::cool::cool:.....



TOOLS NEEDED

HAMMER, FLAT HEAD, SWIVEL ADAPTER FOR BACK SEAT BRACKET BOLTS, 10M TRIPLE SQUARE BIT (I USED A MALE 8MM HEX BIT BUT BE VERY CAREFUL IT CAN STRIP BOLT), 10MM SOCKET, NICE LED HEAD LAMP OR GOOD LIGHTING.

PARTS

2 FUEL PUMPS FOR $168 EACH PASS/DRIVER- ONLINE
1 FUEL FILTER ASSEMBLY $158-ONLINE

TIME

1HR 5MIN. (IN MY DRIVEWAY @NIGHT WHILE RAINING)..I KNOW I NEED AN AWARD OR SOMETHING





step 1. pull tab on rear seats and pop up, then flip forward or towards the front.

step 2. cut carpet, there is a pre cut hole partially present from stock.

step 3. remove 4 10M triple square head bolts on each seat belt bracket(2)

step 4. remove 4 10mm nuts from aluminum lids (2) set lids aside.

step 5. vacuum any dirt and debris around area under lids.

step 6. remove electric plug, and fuel hoses (on both driver and passenger sides) and tuck to the side and out of the way, also keeps rags on deck for gas spillage(use clamp tool to remove fuel line or have strong fingers lol)

step 7. use flat head and hammer to tap brass ring loose. set aside.

step 8. DRIVERS SIDE: pull up fuel filter assembly 3 inches or so and disconnect 2 electrical plugs, let drop in tank, didnt harm anything. this will give you room to pull assembly up more.

step 8A. then remove 2 fuel line from the bottom of the fuel filter assembly. dont worry about mixing up the line because they are two different diameters. leave FF assembly set on top because next step needs to be dont in order to free additional line coming from FFA(fuel filter assembly).

step 9. PASSENGER SIDE: pull up fuel regulator enough to disconnect elec. wires and then remove 2 fuel lines from bottom of regulator. regulator should freely come out, set aside. FUEL TANK RUBBER SEAL(WHICH SEALS FFA/REGULATOR AND TANK) NEEDS TO BE KEPT AS IT CAN BE USED AGAIN.

step 9A. disconnect fuel lines inside of tank, one of which is comes from fuel FFA.

step 10. disconnect fuel lines inside of DRIVERS SIDE TANK, one of which comes from the passenger side fuel pump. FUEL TANK RUBBER SEAL(WHICH SEALS FFA/REGULATOR AND TANK) NEEDS TO BE KEPT AS IT CAN BE USED AGAIN.

step 11. unclip a black hose from top of fuel pump (BOTH DRIVER AND PASS. HAVE THIS HOSE WITH CLIP, WHICH ARE VERY EASY TO UNCLIP.

step 12. man grip the top of pump and turn left 1/4 way til pump releases and remove, BE CAREFUL GAS WILL SPILL FROM PUMPS.

you will use reverse operation to install new pumps. ONLY THING I WILL ADD HERE IS THAT THE RUBBER TANK SEAL NEED TO BE PLACED BEFORE YOU SET FFA/REG. BACK INTO HOLE, AGAIN RUBBER SEAL NEED TO BE SEATED FLUSH AROUND OPENING OF TANK HOLE. THIS CAN BE TRICKY AS YOU HAVE TO HOLD FFA/REG. UP ABOVE TANK HOLE AS YOUR ATTEMPTING TO PLACE TANK SEAL




if you are also installing new FFA then apply as needed. KEEP IN MIND THAT FFA CAN BE OPENED WITH 6 STAR BIT TO CHANGE FILTER INSERT ONLY ($40) VS. ($158 ) FOR NEW FFA FROM EBAY.

** PLEASE NOTE THAT IF YOU DECIDE TO OPEN FFA, THERE IS A RUBBER O RING THAT MUST BE LUBED WITH GAS AND FIT AROUND UPPER PART OF FFA TO PROPERLY PUT BACK TOGETHER. MAKE TRIPLE SURE THAT FFA IS PROPERLY SEALED, ANY LEAKS FROM FFA WILL IN FACT CAUSE ENGINE TO NOT START.

ALSO NOTE THAT I AM NOT RESPONSIBLE IF YOU F THIS UP BECAUSE IT TOOK ME AN HOUR, CONSIDERING I CLEAN CARPETS FOR A LIVING LOL.
 
#3 ·
if you are also installing new FFA then apply as needed. KEEP IN MIND THAT FFA CAN BE OPENED WITH 6 STAR BIT TO CHANGE FILTER INSERT ONLY ($40) VS. ($158 ) FOR NEW FFA FROM EBAY.
I have looked all up and down for the fuel filter element without the plastic flange and can not find one, please put a link up for all of us to this ebay page.


Sent from my SAMSUNG-SM-G920A using Tapatalk
 
#5 ·
Just a heads up that the seat belt anchor bolts have blue thread locker on them. If you do this in the summer it should be soft enough to remove the bolts without too much effort however in the winter you may need to apply a little heat to soften the thread locker. Now another thing to be aware of is that if you have air suspension the air hoses run under the seat back just behind those brackets. Applying heat to those bolts may melt the hoses. You shouldn't have to ask how I know this. :rolleyes:
 
#12 ·
IF ANYBODY FINDS THIS DIY HELPFUL PLEASE DONATE FOR MY NEXT PROJECT....EVEN 1 BUCK, YIN , RUBY, EURO, OR PESO! LOL

http://gofundme.com/dpkevez8
Dude the temp sensor is like $30 and it's under the intake tube, it took me 20 min to replace. If you release the pressure from your cooling system then put the cap back on you won't even loose any coolant. USE A NEW O-RING AND CLIP.

Sent from my SAMSUNG-SM-G920A using Tapatalk
 
#14 ·
When was your timing belt last changed?

If it's more than, say, three years old then given what you are doing I'd very seriously consider replacing it along with the tensioners, water pump and thermostat.
 
#21 ·
Great post. Thank you and to everyone on this forum. Couldn't have done it without you. And it was a bltch!
Replaced both fuel pumps, fuel filter, flange/regulator, and gaskets. The 2005 3.2L would die seconds after starting just fine. Odometer reads 150k. I decided to replace all because of the age of the vehicle and to hopefully prevent from having to go at it again.
Parts Ordered
2005 Volkswagen Touareg Fuel Filter Price: $100.43 Qty: 1 Part #: 229-025-003-001Z
2005 Volkswagen Touareg Fuel Pump Assembly Price: $264.58 Qty: 1 Part #: W0133-1849441
2005 Volkswagen Touareg Fuel Pump Assembly Price: $220.58 Qty: 1 Part #: W0133-1829221
2005 Volkswagen Touareg Fuel Pump Tank Seal Price: $20.18 Qty: 2 Part #: TS8062
2005 Volkswagen Touareg Fuel Pump Flange Price: $90.58 Qty: 1 Part #: W0133-2107191

Sub Total:
$716.53
Shipping:
$52.88 <<<ordered Tuesday- received Thursday

Tax:
$0.00
Total:
$769.41
 
#22 ·
Greetings all. Great write up here. I was trying to follow a youtube video that was pretty good, but im stuck on reassembly. Has anyone run into trouble with a connector from the new pump not fitting to an old hose? I'm down to one female connector on a new pump and one male line on an old brown hose from inside the tank somewhere and they dont go together? what have i done? lol I have a 2005 VW touareg, v6. swapping both pumps and filter assembly. I'be been at this over 6 hours so far. please anyone help?

Dave
 
#23 ·
#24 · (Edited)
this is a non mechanic version on how to change the fuel pumps and also insight on some of the fuel systems major components.

DEALER WANTED 2500 TO DO THIS JOB. I SAID F YOU PAY ME:cool::cool::cool::cool:.....



TOOLS NEEDED

HAMMER, FLAT HEAD, SWIVEL ADAPTER FOR BACK SEAT BRACKET BOLTS, 10M TRIPLE SQUARE BIT (I USED A MALE 8MM HEX BIT BUT BE VERY CAREFUL IT CAN STRIP BOLT), 10MM SOCKET, NICE LED HEAD LAMP OR GOOD LIGHTING.

PARTS

2 FUEL PUMPS FOR $168 EACH PASS/DRIVER- ONLINE
1 FUEL FILTER ASSEMBLY $158-ONLINE

TIME

1HR 5MIN. (IN MY DRIVEWAY @NIGHT WHILE RAINING)..I KNOW I NEED AN AWARD OR SOMETHING





step 1. pull tab on rear seats and pop up, then flip forward or towards the front.

step 2. cut carpet, there is a pre cut hole partially present from stock.

step 3. remove 4 10M triple square head bolts on each seat belt bracket(2)

step 4. remove 4 10mm nuts from aluminum lids (2) set lids aside.

step 5. vacuum any dirt and debris around area under lids.

step 6. remove electric plug, and fuel hoses (on both driver and passenger sides) and tuck to the side and out of the way, also keeps rags on deck for gas spillage(use clamp tool to remove fuel line or have strong fingers lol)

step 7. use flat head and hammer to tap brass ring loose. set aside.

step 8. DRIVERS SIDE: pull up fuel filter assembly 3 inches or so and disconnect 2 electrical plugs, let drop in tank, didnt harm anything. this will give you room to pull assembly up more.

step 8A. then remove 2 fuel line from the bottom of the fuel filter assembly. dont worry about mixing up the line because they are two different diameters. leave FF assembly set on top because next step needs to be dont in order to free additional line coming from FFA(fuel filter assembly).

step 9. PASSENGER SIDE: pull up fuel regulator enough to disconnect elec. wires and then remove 2 fuel lines from bottom of regulator. regulator should freely come out, set aside. FUEL TANK RUBBER SEAL(WHICH SEALS FFA/REGULATOR AND TANK) NEEDS TO BE KEPT AS IT CAN BE USED AGAIN.

step 9A. disconnect fuel lines inside of tank, one of which is comes from fuel FFA.

step 10. disconnect fuel lines inside of DRIVERS SIDE TANK, one of which comes from the passenger side fuel pump. FUEL TANK RUBBER SEAL(WHICH SEALS FFA/REGULATOR AND TANK) NEEDS TO BE KEPT AS IT CAN BE USED AGAIN.

step 11. unclip a black hose from top of fuel pump (BOTH DRIVER AND PASS. HAVE THIS HOSE WITH CLIP, WHICH ARE VERY EASY TO UNCLIP.

step 12. man grip the top of pump and turn left 1/4 way til pump releases and remove, BE CAREFUL GAS WILL SPILL FROM PUMPS.

you will use reverse operation to install new pumps. ONLY THING I WILL ADD HERE IS THAT THE RUBBER TANK SEAL NEED TO BE PLACED BEFORE YOU SET FFA/REG. BACK INTO HOLE, AGAIN RUBBER SEAL NEED TO BE SEATED FLUSH AROUND OPENING OF TANK HOLE. THIS CAN BE TRICKY AS YOU HAVE TO HOLD FFA/REG. UP ABOVE TANK HOLE AS YOUR ATTEMPTING TO PLACE TANK SEAL




if you are also installing new FFA then apply as needed. KEEP IN MIND THAT FFA CAN BE OPENED WITH 6 STAR BIT TO CHANGE FILTER INSERT ONLY ($40) VS. ($158 ) FOR NEW FFA FROM EBAY.

** PLEASE NOTE THAT IF YOU DECIDE TO OPEN FFA, THERE IS A RUBBER O RING THAT MUST BE LUBED WITH GAS AND FIT AROUND UPPER PART OF FFA TO PROPERLY PUT BACK TOGETHER. MAKE TRIPLE SURE THAT FFA IS PROPERLY SEALED, ANY LEAKS FROM FFA WILL IN FACT CAUSE ENGINE TO NOT START.

ALSO NOTE THAT I AM NOT RESPONSIBLE IF YOU F THIS UP BECAUSE IT TOOK ME AN HOUR, CONSIDERING I CLEAN CARPETS FOR A LIVING LOL.
Great instructions
I’m right in the midst of this job right now on my 2004 .
I would only add the caveat , “The lines that come out of the top of the fuel pumps and attach to their respective passenger and driver side module and fuel filter are ZIP TIED FOR A REASON, to allow the module and fuel filter assembly unit easier maneuverability when repositioning them

I am finding out the hard way how flimsy these plastic moldings are on said units

đź‘€
 
#25 ·
Great instructions
I’m right in the midst of this job right now on my 2004 .
I would only add the caveat , “The lines that come out of the top of the fuel pumps and attach to their respective passenger and driver side module and fuel filter are ZIP TIED FOR A REASON, to allow the module and fuel filter assembly unit easier maneuverability when repositioning them

I am finding out the hard way how flimsy these plastic moldings are on said units