User Manual Q&AAnswer
Feb 16, 2025 - 09:30 PM
To install the DW65v fuel pump on your Audi/VW 1.8T FWD, please follow the steps below:
1. Unplug the electrical connectors: Both connectors have tabs that need to be pushed in as the connector is pulled up.
2. Remove the screws: Remove the screws that attach the top of the assembly to the bucket. These screws can be either a 7mm hex or T20 torx.
3. Pry the clamp loose: Pry the head of the clamp loose enough to pull the hose away from the pump and upper assembly. The hose may need to be cut for removal.
4. Remove the bucket cap: Lift up the 4 tabs around the top of the bucket cap. The pump will come out with the cap with a gentle pull.
5. Install the o-rings: Install the 3 supplied o-rings on the DW65v fuel pump. Use a generous amount of Super Lube for smooth installation.
6. Properly position the larger lower o-ring: The larger lower o-ring should be placed below the lip and leave the rectangular port on the cap exposed. Placing the larger lower o-ring in the groove will block the port and cause fuel starvation, engine stalling, and pump damage.
7. Install the DW65v fuel pump: Insert the DW65v fuel pump into the assembly and replace the bucket cap. Ensure that the small circle inside the bottom of the DW65v aligns with the matching circle in the bucket (black and green arrows).
8. Install the new fuel hose: Install the new fuel hose supplied with the DW65v onto the pump and then connect it to the top of the assembly.
9. Reinstall the top and connect the wires: Reinstall the top of the assembly and connect the wires to the DW65v fuel pump.
10. Reinstall the assembly into the fuel tank: Attach a length of hose to the outlet of the pump assembly, allowing it to drain into a fuel-safe container. Prime the fuel pump assembly.
11. Cycle the key to the on position: Cycle the key to the on position multiple times to prime the pump assembly and evacuate any air introduced during the installation process.
12. Attach the supply line: Attach the supply line to the outlet of the pump assembly.
Please note that this installation guide is intended to aid in the installation process. It is recommended to consult the factory manuals or instructions for your specific vehicle to remove the fuel pump assembly.
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