Note: This is a general guide and may not apply to your vehicle.
How to Replace a Fuel Pump
for the 2002 Volkswagen Jetta TDI 4 Cyl 1.9L change
Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or closed toe shoes.
Park the vehicle on a solid, level surface and set the parking brake.
On most vehicles, the electric fuel pump is located in the fuel tank. Open the fuel cap and have an assistant turn the key to the ON position while you listen at the filler opening. The fuel pump will hum for two to three seconds if the pump is working. If the fuel pump does not make a sound, replacing the pump may be necessary.
Locate and check the fuel pump fuse and relay.
If the fuse is blown, replace it with a fuse of the same amperage. Check fuel pump operation. If the fuel pump works, you've solved the problem.
If the fuse and relay are okay, check for power and ground at the fuel pump. Removing the fuel tank or the back seat may be necessary. If there is power and ground at the pump, then the pump is defective.
Relieve the fuel system pressure. Disconnect the negative battery cable.
Siphon or drain as much fuel as possible from the fuel tank. Disconnect the filler tube hose and the electrical connection to the pump.
Support the fuel tank with a jack and a block of wood. Remove any retaining straps or bolts holding the tank to the frame. Lower the tank.
Disconnect the fuel lines and remove the fuel pump from the tank.
Compare the new fuel pump with the original to verify that you have the correct part. Install the new fuel pump.
Connect the fuel lines to the pump. Lift the fuel tank up and install the retaining strap. Reconnect the filler tube hose and the electrical connector.
Reconnect the negative battery cable. Fill the tank with gas. Road test the vehicle to verify the repair.
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