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created by Phil Ade 02.01.2008

Removing and Re-installing the Fuel Pump (1600i Mexican Beetle)

 

 

Prerequisites:-

 

The following tools are required to remove the fuel pump:-

 

-         Two flat blade screwdrivers (to be used as levers)

-         Plastic hose clamp (do not use Molegrips nor any metal clamps !!)

-         Long nose pliers (to remove the fuel hoses)

-         Small flat blade screwdriver (to undo and redo fuel hoses)

-         Molegrips or a strong pair of cutters (to cut off the old fuel hose clips if necessary).

 

 

The fuel pump is located on the front left hand side of the car shown below:-

 

 

The fuel pump is located behind the front shock absorber, next to the speedometer cable.

 

 

 

 

Before attempting to remove the fuel pump, you will need to do the following:-

 

-         Jack up the car and remove the front left roadwheel

-         Turn the steering wheel fully clockwise to gain access to the fuel pump


 

The fuel pump can now be removed.To fuel pump is secured by three rubber bushes, which are mounted onto three mounting pegs on the chassis.

 

 

 

 

To remove the fuel pump, you will need two flat blade screwdrivers to lift the fuel pump off itís mounting pegs.The photo below shows the fuel pump partially lifted out of itís mounting pegs:-

 

 

 

 

Lever up the fuel pump gradually from one mounting peg at a time.After the fuel pump has been lifted out of itís mounting pegs, the fuel hoses can now be disconnected.

 

Use a plastic hose clamp on the fuel hose from the fuel tank to prevent fuel from spilling out everywhere !!!†† Now remove the fuel hoses from the fuel pump, if necessary cut off the old fuel hose clips but do not damage the fuel hoses !!Pry off the fuel hoses carefully with a pair of long nosed pliers and pull off the fuel hoses at the same time.


This is what the fuel pump mounting (and fuel hoses) looks like after the fuel pump has been completely removed from the car:-

 

 

The fuel hoses should fit exactly the same way as they were removed.This is what the fuel pump looks like:-

 

Fuel pump connections:-

 

Top Centre = Fuel pump outlet

Top Outer†† = Fuel pump return

††††††††††††††††††††† (to fuel tank)

Side Upper = From fuel pressure

††††††††††††††††††††† regulator

Side Lower = From fuel tank

 

 

The fuel pump can now be reinstalled back into the car and the fuel hoses can be reconnected.To reinstall the fuel pump, simply put the fuel pump into position and push it into place.

 

Before reconnecting the fuel hoses onto the new fuel pump, make sure that the hose ends are clean.Once you have reconnected the fuel hoses and have reinstalled the fuel pump, release the plastic hose clamp from the fuel tank hose.

 

This is what the fuel pump looks like when itís reinstalled back into the car:-