DW65v Audi/VW 1.8T FWD DW65v Fuel Pump Installation Guide
- June 3, 2024
- DW
Table of Contents
DW65v Audi/VW 1.8T FWD DW65v Fuel Pump
Audi/VW 1.8T FWD DW65v Fuel Pump Installation Guide
PLEASE READ – this guide is intended to aid in the installation of our products. It is recommended that factory manuals or instructions are followed to remove the fuel pump assembly from the vehicle. Some instructions in this guide are generic. The factory manual should supersede any contradiction. This kit uses PTFE tubing and permanent clamps. Heat from a heat gun, high temperature hair dryer, or boiling water may be used to soften the tubing ends to make installation onto the pump and assembly easier. DO NOT USE AN OPEN FLAME! The permanent clamps may be crimped with end cutters or side cutters. PTFE tubing installation video: https://www.youtube.com/watch?v=6NE6tRE1Kug The smaller permanent hose clamp is not used with the FWD models. Below is a picture of suggested tools that will make the installation process easier:
Fuel Pump Installation
- unplug the electrical connectors, both connectors have tabs that need to be pushed in as the connector is pulled up
- remove the screws that attach the top of the assembly to the bucket, these screw can be either a 7mm hex or T20 torx
- pry the head of the clamp lose enough to pull the hose away from the pump and upper assembly; the hose may need to be cut for removal
- removed the bucket cap by lifting up the 4 tabs around the top (circled in green), the pump will come out with the cap with a gentle pull
- install the 3 supplied o-rings on the DW65v, use a generous amount of Super Lube for smooth installation
- The proper location for the larger lower oring is below the lip and leaves the rectangular port on the cap exposed (circled in green) Placing the larger lower oring in the groove, blocks the port and prevents the assembly from scavenging the outside fuel. This will cause the pump to starve, the engine to stall, and will damage the pump.
- The proper location for the larger lower oring is below the lip and leaves the rectangular port on the cap exposed (circled in green) Placing the larger lower oring in the groove, blocks the port and prevents the assembly from scavenging the outside fuel. This will cause the pump to starve, the engine to stall, and will damage the pump.
- install the DW65v into the assembly and replace the bucket cap, the small circle inside the bottom of the 65v needs to be aligned with he matching circle in the bucket (black and green arrows)
- install the new fuel hose supplied on the 65v and then install to the top of the assembly
- reinstall the top and connect the wires to the DW65v
- reinstall the assembly into the fuel tank and attach a length of hose to the outlet of the pump assembly allowing it to drain into a fuel safe container and prime the fuel pump assembly
- cycle the key to the on position as many times as required to prime the pump assembly and evacuate the air introduced during the pump installation process
- attach supply line to the outlet of the pump assembly