Right there are many threads on this but there is nothing set on stone how to do this properly keeping the fuel gauge reading correctly (at least in the same thread anyway), so I thought I would write one for you all.
Now first thing you need to do is get your hands on an LCR/TT/S3 fuel pump. It is easier to get an LCR as if you get a TT/S3 you will have to block off the extra feed for the Quattro system.
Technically they are a straight fit, but to keep the fuel gauge reading correctly you need to swap the float from the standard fuel pump onto your new 4bar fuel pump.
Before you do this you may want to make sure you don't have over a half a tank of fuel, this is not necessary but it means it's easier at keeping it a clean job.
So what you need to do in order (move to step 6-8 if you can get the pump out and want to know how to change the floats):
1. Remove the lower half of the rear seats to gain access to the fuel pump. This is done by removing the 2 5mm allen key bolts. You don't have to remove it but good luck to you if you dont!
2. Now that that's out of the way, remove the cover for the fuel pump compartment (under the flappy bit of carpet) by removing the 3 star head screws.
3. Now you will need to disconnect all the the fuel lines and the electrical connector (you might want to keep a cloth handy as some fuel will come out of these). This is done by squeezing the connectors (you will see what I mean).
4. Try and get all of the hoses tucked out of the way as you will now need to remove the large plastic ring holding the fuel pump in place. I use a screwdriver and hit it round as it is fiddly to get your hand in and around without causing yourself serious pain!
5. Now once you get this off the pump will lift out of place. Be careful when removing the final bit of the pump as the float might get caught, and you don't want to bend/break it. Also be careful not to spill the fuel that will still be inside the pump.
6. Now it's time to change the floats. On the back of the pump you will see 4 torx screws and a circuit board. What you need to do is disconnect the 2 wires that go to this circuit board (clips hold the connectors in place, these will need to be depressed with a small pointed object).
7. Now you will need to lift up the flaps at the top of the square shaped plastic piece the circuit board and float are attached to. You will need a small flat headed screw driver or something similar to do this. Then the piece will slide downwards and come away from the pump. This is all you need off the old pump.
8. Now do the same on your new 4 bar pump and then replace with your old Ibiza float.
Now to get the pump back into the tank can be a PITA but with time and patience you will get there. What I found if you mark where the plastic rings thread starts and where the thread starts on the tank it makes the process easier.
9. Place the fuel pump into the tank making sure that float does not get caught on anything. You want to make sure that the arrows on the pump are facing the arrows on the car, otherwise (as I found out) the car won't start!), Also make sure the pump is fully seated and that the seal is in the hole properly as you won't be able to go onto the next stage if not.
10. Now time for the fiddly bit! Getting the ring on. You want to try and hold down the pump at the same time as spinning on the ring. Another set of hands sometimes helps if you can coordinate who goes where! But if you had marked the 2 threads you know where the 2 threads start so it helps you out. It will take you a few goes as you will find when you get a half turn of the thread back on it just pops off again. You will need to push down on the pump again and really make sure it's in there.
11. Once you get this back on all you need to do is connect up the right hoses/wire to the right places. I would suggest trying to start the car before putting the cover and seat back on, if it doesn't start you may have the pump in the wrong position or the hoses wrong. While starting hold the ignition until you here the fuel pump starting for a little longer just to make sure there is enough fuel circulating through the system.
12. After you are satisfied everything is ok you can put everything back on and enjoy the smell of petrol in your car for a few days!!
I will try and get pictures of some of the steps as I know that changing the floats over was a bit of a mystery to me for a while until I actually got the pump out again and had a proper look at it.
Hope this helps and thanks for reading!
Now first thing you need to do is get your hands on an LCR/TT/S3 fuel pump. It is easier to get an LCR as if you get a TT/S3 you will have to block off the extra feed for the Quattro system.
Technically they are a straight fit, but to keep the fuel gauge reading correctly you need to swap the float from the standard fuel pump onto your new 4bar fuel pump.
Before you do this you may want to make sure you don't have over a half a tank of fuel, this is not necessary but it means it's easier at keeping it a clean job.
So what you need to do in order (move to step 6-8 if you can get the pump out and want to know how to change the floats):
1. Remove the lower half of the rear seats to gain access to the fuel pump. This is done by removing the 2 5mm allen key bolts. You don't have to remove it but good luck to you if you dont!
2. Now that that's out of the way, remove the cover for the fuel pump compartment (under the flappy bit of carpet) by removing the 3 star head screws.
3. Now you will need to disconnect all the the fuel lines and the electrical connector (you might want to keep a cloth handy as some fuel will come out of these). This is done by squeezing the connectors (you will see what I mean).
4. Try and get all of the hoses tucked out of the way as you will now need to remove the large plastic ring holding the fuel pump in place. I use a screwdriver and hit it round as it is fiddly to get your hand in and around without causing yourself serious pain!
5. Now once you get this off the pump will lift out of place. Be careful when removing the final bit of the pump as the float might get caught, and you don't want to bend/break it. Also be careful not to spill the fuel that will still be inside the pump.
6. Now it's time to change the floats. On the back of the pump you will see 4 torx screws and a circuit board. What you need to do is disconnect the 2 wires that go to this circuit board (clips hold the connectors in place, these will need to be depressed with a small pointed object).
7. Now you will need to lift up the flaps at the top of the square shaped plastic piece the circuit board and float are attached to. You will need a small flat headed screw driver or something similar to do this. Then the piece will slide downwards and come away from the pump. This is all you need off the old pump.
8. Now do the same on your new 4 bar pump and then replace with your old Ibiza float.
Now to get the pump back into the tank can be a PITA but with time and patience you will get there. What I found if you mark where the plastic rings thread starts and where the thread starts on the tank it makes the process easier.
9. Place the fuel pump into the tank making sure that float does not get caught on anything. You want to make sure that the arrows on the pump are facing the arrows on the car, otherwise (as I found out) the car won't start!), Also make sure the pump is fully seated and that the seal is in the hole properly as you won't be able to go onto the next stage if not.
10. Now time for the fiddly bit! Getting the ring on. You want to try and hold down the pump at the same time as spinning on the ring. Another set of hands sometimes helps if you can coordinate who goes where! But if you had marked the 2 threads you know where the 2 threads start so it helps you out. It will take you a few goes as you will find when you get a half turn of the thread back on it just pops off again. You will need to push down on the pump again and really make sure it's in there.
11. Once you get this back on all you need to do is connect up the right hoses/wire to the right places. I would suggest trying to start the car before putting the cover and seat back on, if it doesn't start you may have the pump in the wrong position or the hoses wrong. While starting hold the ignition until you here the fuel pump starting for a little longer just to make sure there is enough fuel circulating through the system.
12. After you are satisfied everything is ok you can put everything back on and enjoy the smell of petrol in your car for a few days!!
I will try and get pictures of some of the steps as I know that changing the floats over was a bit of a mystery to me for a while until I actually got the pump out again and had a proper look at it.
Hope this helps and thanks for reading!
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