Guidance needed- replacing fuel pump on 2004.5 Passat 4- motion 1.8T manual shift

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  1. #1
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    Guidance needed- replacing fuel pump on 2004.5 Passat 4- motion 1.8T manual shift

    I've reviewed all the write ups and threads on replacing Fuel pumps on Passats, and it looks fairly straight forward.... although working on my 4-motion variant seems different than the pictures I've seen. I started in the cargo are, near the spare tire well, where I saw a black access panel. I removed the panel, and unscrewed the black ring.. it yield no fuel pump, but a fuel sensor.<p>


    Then I ventured under the rear passenger bench, where there were two black access panels, one under each seat. The right side had some wires running to it, the left side did not:


    The right side looks to be the fuel pump, although removing the electrical plug/harness is daunting :


    The left side panel reveals this item, although I am unsure what it is:


    This is the fuel pump that was sent to me for my particular model (according to ECS Tuning):


    So, am I barking up the right tree? Your confirmation, or corrective advice, would help me out a bunch, if not help me sleep a bit better and I can tackle this tomorrow with confidence.

    Thank in advance!

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  3. #2
    Grinding Gears...gone fishing! ScottPassat2.8's Avatar
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  4. #3
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    Looks like a fuel pump, but I have not had to change one on a 4MO. The 2nd may be a secondary pump to move fuel between the 2 sides of the saddle tanks, or it is another level sensor.

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  6. #4
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    I removed the plug, and both hoses lead to the cavity. If I had to do it again, I would remove the seat cushion to give more room. Also, I recommend setting up a house fan in the car with all windows and doors open to get fresh air in there. Anyways, removing the white disk gets you into the tank itself, and look what you find:



    Getting the pump out was the biggest challenge, even though you 'only' need to turn it less an inch counter-clockwise. Once out, I bench tested the pump to re-confirm it truly was the pump (confirmed), and began the process of installing new pump. 15 minutes later I was taking the car for a test drive.

  7. #5
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    Quote Originally Posted by clerkkent View Post
    I removed the plug, and both hoses lead to the cavity. If I had to do it again, I would remove the seat cushion to give more room. Also, I recommend setting up a house fan in the car with all windows and doors open to get fresh air in there. Anyways, removing the white disk gets you into the tank itself, and look what you find:



    Getting the pump out was the biggest challenge, even though you 'only' need to turn it less an inch counter-clockwise. Once out, I bench tested the pump to re-confirm it truly was the pump (confirmed), and began the process of installing new pump. 15 minutes later I was taking the car for a test drive.

    wow you tank is full of gas, not really the best idea to run the failed pump outside with the fumes and gas. but still you DIY it.

  8. #6
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    I'm not crazy.. I bench tested it.. in that I took it to the workbench in my garage and hooked it up to a 12V battery, far away from the open gas tank.

    The gas gauge showed I only had 1/2 tank of gas, yet this tank was full. I guess on the saddle tanks for AWD vehicles, the car uses up the left tank first, then uses the right tank up.

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