1.8T 2wd Fuel Pump Fitting Guide
It’s common knowledge that the Standard fuel pump on the 1.8t (especially that in the k03s powered cars) is a weak point when trying to push for more power. What isn’t always taken into consideration is that our 1.8t powered cars are starting to get old and the standard pump can become worn out and not perform as well as they should. For this reason knowing how to replace it is a vital piece of information! Which is why we have decided to create a little guide. Changing the fuel pump Is actually easier then you may think and can being done in as little as 30-40mins on your own driveway! For more info on fuel pumps and the available upgrades take a look out the Fuel pump info page
Disclaimer – 18t-tuning take no responsibility for any damage to property or persons that may occur while this guide is being used. You do so at your own risk.
Beware – While following this guide you will be working on the fuel system of the car. As you know this is a pressurised system, petrol is highly flammable and the fumes can overwhelm you.
Lets get started
Replacement fuel pump
Fitting kit including – New O-rings, 8-12mmjubilee clips/o clip and fuel pump line
10mm spanner (to disconnect battery)
Large Philips screw driver
Either large plumbers pliers or Large flat blade screwdriver/blunt chisel and mallet
Small flat head screwdriver
T20 (???) torx driver
Cardboard for the Ground
It is best to undertake this job with the fuel tank as low as possible to minimise fuel spillages.
- We first need to start by depressurising the fuel system. We do this by removing the fuel pump fuse and then starting the engine. The engine will jump into life as per usual and then proceed to cut out a few second later.
The fuel pump fuse is fuse number 28 which can be seen in the image below.
- Disconnect the battery
- Lift the rear bench behind the drivers seat and notice a flap in the carpet, lift this to expose the fuel pump access hatch.
- Remove the 3 screws using the Philips screwdriver, keep safe and remove cover plate.
- Unplug the large black plug from the top of the fuel pump. Do this by pushing down on the plug as to push it “more on” and then pressing the small tab in on the side before pulling the plug off
- It may be a good idea to note which pipe is flow and which is return (as indicated by the small arrows on the plastic) and mark one so you know which is which.
- Remove the two pipes by pushing in a little tab on the side of the connector whilst pulling the pipe (see image below). It may be necessary to spray the connectors with some carb cleaner to get the clips to press in fully. You may also need to push the pipe and pull it again while pressing the clip to release the connector.
- Move the pipes and wiring out of the way and undo the big black ring nut. Do this by either using a large pair of plumber pliers or by using a large screw driver or blunt chisel and mallet to tap the ring free.
*For the next step ensure you have your nitrile gloves on as you will likely come into contact with fuel. Also place your cardboard on the driveway and have your rags at the ready!
- The pump can now be carefully removed, taking extra care not to damage the fuel level float lift the pump and tilt it so it can be removed. Be aware that the pump will store a lot of fuel so let it drain as much as possible before removing it fully from the tank.
- Once you have the pump out place it on the cardboard (ignore the image I placed it onto cardboard afterwards) on your driveway. We advice you try to do this outside as to not cause a risk of excess fumes and fire risk inside a garage.
- Next we need to remove the 4 torx screw located on the back of the fuel pump housing. see below
- After the 4 screws have been removed the back of the pump basket will come away from the body. Bring the back up above the pump, take note of the wires, pipes and their positions.
Remove the two spade connectors from the top of the pump. The yellow wire will pull straight off, the black wire needs the locking tab pushing to disconnect it.
Remove the one time O-clip from the feed pipe on the pump (the image has a small jubilee has it has been removed before). The feed pipe can be quite stubborn but it will go! If you have a new feed pipe with your new pump you can slice the old pipe with a Stanley to aid removal.
- Now you can remove the top of the pump basket. Using a small flathead screwdriver pry the three tabs around the top edge of the basket and remove.
- The pump itself will now pull out of the basket. The next job is to clean the internal mesh inside the pump basket (as seen in the image below) using electrical/carb cleaner. These can become very blocked so its worth making sure they are clean! Just be careful not to damage them. Also remove the round pickup screen from the bottom of the pump basket and give that a clean too!
- Before installing the new pump we need to fit the three new O-rings. One fits inside the bottom of the fuel pump itself. the next one goes around the bottom of the fuel pump. These two can be seen in the image below. The last one goes inside the top of the pump basket. This can be seen in the image of step 13.
- When you fit the pump into the basket push it all the way down and then take your pick up screen and align the pumps pick up with the screens pick up pipe . Once aligned click the screen back into place.
This is where sometimes problems can occur, if this screen is not removed when installing a new pump then the pick up pipe and the pump can be misaligned which will make the pump sit higher. This will make the pump not use the pick up pipe of the bottom screen and you can end up with an issue where the car cuts out while you still have fuel in the tank (usual cut out point is approx 1/4 of the fuel tank)
- Reference for how low the pump should sit.
- Refit the lid of the basket ensuring the O-ring slides over the pump. The pump should sit flush like below.
- Next refit the feed pipe, securing with a 8-12mm jubilee clip or suitable O-clip.
- Reattach the black and yellow wires to the pump and the 4 screws which secure the fuel sender to the basket.
- To finish off refit the pump basket into the fuel tank by doing the reverse of how you removed it (step 9 – 3)
- Reconnect the battery and replace fuel pump fuse#
- Prime the fuel lines by switching the ignition on and off a couple of times so you can hear the pump priming.
- Start the car and enjoy your new fuelling headroom!