Thread: Dying 3.9 V8 fuel pump

I suspect the fuel pump on my D1 is on its way out. After about an hour of driving, it goes from sounding normal to sounding like an aeroplane taking off. There is a coincident loss of power/stumble from the engine when I put the foot down or try to go uphill.

I've read up on the RAVE and previous threads, job seems easy enough, but my tank is currently about 1/3 full. Do I need to empty it to swap out the pump? Do I need the special tool to remove the retaining ring?

Post-script: I appreciate this has likely been done to death but its my first petrol from 6 years ownership of a Tdi

Originally Posted by bee utey

You can tap the pump assembly locking ring around with a hammer and blunt screwdriver, or make a tool with two legs to straddle the ring and turn it with a socket set. The most critical part of replacing the pump inside the assembly is to salvage the original corrugated pressure hose. I've removed the pump from the swirl pot, laid the pump outlet on a block of hardwood, and carefully broken the pump spigot by hitting it with a hammer, while still connected to the hose. When the pump fitting has shattered you can remove the bits and use a regular clamp to fit the hose to the new pump. I use a Bosch pump kit part no. BFP772. It comes with a replacement harness connector which you need to connect to the original cable with two crimp terminal joiners.

If the original pressure hose is not salvageable, you need to get some submersible EFI fuel hose. This is expensive and hard to find. Regular EFI hose will swell up and burst within a couple of weeks.

Here is the Ebay site: 5 16" Submersible IN Tank Fuel Line Hose SAE30R10 Specs | eBay