[Iowegian]

2001.5 B5.5 wagon, 1.8T ATW.

My daughter had the car out of state and had the fuel pump go out on her. The car was towed to a mechanic who installed a new fuel pump (ouch$$) Afterwards, the car ran fine until there was a 'bang' then a sound like an exhaust leak. She got the car home and I found that the main air intake hose had come off from the intake manifold. I re-attached the hose, tightened the clamp and cleared all the codes. Now, I'm getting a P0442 errors (evap system error) and there is a noticeable gasoline smell. The smell seems to be getting better and I'm hoping it's from spilled gas during the pump replacement. I re-seated the tank access cover inside the car and that seemed to help the smell.

I know I need to check all the evap lines, etc to try to track down the P0442 errors but is it possible that the 'bang' was caused by some gas vapors getting into the intake somehow? Any ideas on what evap components might have gotten damaged during the pump replacement? I'm hoping the P0442 fix is as simple as the non-attached hose fix but I'm concerned about missing something or that I'm getting excessive un-burned vapors into the intake.

 

[Tomvw]

16826/P0442/001090 - Ross-Tech Wiki

Check that the fuel pump cover is properly sealed.

 

[Iowegian]

Check that the fuel pump cover is properly sealed.

That appears to be the cause of the fuel leak. While working on it, I discovered that the hose clamp for the fuel outlet line was over-tightened and snapped. I fixed that and the P0442 is gone. However, the cover is still leaking gas so I'll check/tighten that next. I also need to replace the broken electrical connector on top of the pump cover since it was destroyed while being removed. Finally, I re-installed the wheel well cover on the rear passenger side since it had been removed for some reason and re-installed by just drilling through the plastic bumper, etc instead of aligning the screw holes with the plastic inserts. With all due respect to the professional mechanics here, this is why I prefer to do my own work when it is within my capabilities. Having the advice and resources of PassatWorld sure help too :thumbup:

 

[Iowegian]

Took a look at it over lunch since I'm getting tired of the smell of gasoline...and it was indeed an improperly sealed pump cover. There is a large rubber sleeve gasket type of thing that just fell out when I lifted the cover so I'm pretty sure that was where it was leaking. I put it all back together and so far, it's still dry. Finally. I'm also a bit relieved about the busted electrical connector since the wires press up against the cover plate. Hopefully the pressure will keep the connector in place until I have time to source a new one and put it in.

For anyone doing this job in the future, here are a few tips I learned along the way:
It's an easy job but it does involve gasoline so take some precautions. ALWAYS run down the system pressure before dis-connecting anything by removing the fuel pump fuse (#28 I think) or disconnecting the connector and then cranking the car a few times to drop the fuel line pressure. Expect some residual pressure and have a rag handy when you open any fuel line. Even on a wagon, access is easier from the side door rather than the back. Put the rubber gasket into the tank and then insert the cover into it. Don't put the gasket on the cover then try to insert them together. If you do it right, the cover will make a nice tight squeek when it is inserted into the rubber sleeve. You can also run your finger around the lip after the cover is in to verify it is seated correctly. Replacing the fuel filter is probably a good idea when replacing the pump. I'd do it after a tank of gas or so since it is almost impossible not to get a bit of dust or dirt into the tank. Everything is a pretty tight fit and the top of the tank will be dirty. If I was doing it again, I'd try to clean the top up before starting dis-assembly.
Finally, here are some pictures here that show what is involved, at least for a non-4Mo V6 or 1.8. The rubber gasket that was giving me problems can be seen in the bottom of the photo between steps 8 and 9.
V6 Fuel Pump Removal Replacement - PassatB5

 

[ylwagon]

If I was doing it again, I'd try to clean the top up before starting dis-assembly.

Absolutely, I wouldn't attempt to open that tank cover and hoses until washed and dried. Any soapy water you pour/brush there will just drain out under the car. By the way, those photos from the link show a horribly dusty situation. Another thing, at least on my A4, is the plastic ring nut has a mark on the top which is opposite the starting thread below. It makes aligning the threads of the tank easier.

 

[jjpark]

Good post. Ummm need to clean up those Amp wires ;-)