Tandem Pump
Tandem Pump
DANGER!
The tandem pump must not be disassembled under any circumstances because it can cause the vacuum part to malfunction. The result would be brake booster failure.
CAUTION!
Pay attention to the notes when re-installing a running tandem pump.
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1331)
• Diesel extractor (VAS 5226) or hand vacuum pump (6213) or hand vacuum pump (V.A.G 1390) and
• Draining container (V.A.G 1390/1)
• Spring-type clip pliers (VAS 5024A)
Removing
Read safety precautions before beginning work => [ Fuel Supply System Safety Precautions ] Fuel Supply System Safety Precautions.
Observe the rules for cleanliness => [ Clean Working Conditions ] Fuel Supply System.
- Turn the ignition and all electrical consumers off and remove the ignition key.
- Remove engine cover.
One Piece Engine Cover
Pull the one piece front engine cover - arrows A - upward with a quick jerk and then pull the lower mount - arrow B - forward.
Two Piece Engine Cover
On the two piece engine cover, first pull the outer cover upward with a quick jerk - arrows in the upper illustration -, then pull the inner engine cover upward with a quick jerk - arrows in lower illustration -.
- Disconnect electrical harness connector - 2 - at Mass Air Flow (MAF) sensor (G70).
- Disconnect the ventilation hose - 1 - and disengage it from the bracket - arrow -.
- Open the spring-type clip- 3 - using spring-type clip pliers (VAS 5024A) and disconnect the intake hose from the Mass Air Flow (MAF) sensor (G70).
- Disconnect the intake manifold - 5 - from the air guide.
- Unfasten bolt - 4 - and remove air filter housing and mass air flow sensor.
- Carefully cut the cable tie - 1 -.
- Open the wiring bracket - 2 - and disengage the wiring harness.
- Remove both bolts - arrows - from the upper charge air pipe - A -.
- Remove noise insulation
- Remove the charge air pipe bolt - arrow -- A - from the oil pan.
CAUTION!
• The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
• In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
• Wear protective goggles and protective gloves when working on the fuel system!
- Pull off the supply hose (white marking) and the return hose (blue marking) from the fuel filter.
- Connect the diesel extractor (VAS 5226) or the hand vacuum pump to the draining container (V.A.G 1390/1) on the return hose - 2 -.
- Operate the diesel extractor (VAS 5226) or the hand vacuum pump, until fuel stops coming our of the return hose. Make sure no fuel gets into the hand vacuum pump.
- Disconnect vacuum line of brake booster - 1 - from tandem pump - 4 -.
- Disconnect supply hose - 2 - (white marking) and return hose - 3 - (blue marking) from tandem pump - 4 -.
- Remove mounting bolts - arrows -.
- Remove tandem pump - 4 - from cylinder head.
Installing
Installation is performed in reverse order. When doing this note the following:
• Make sure that tandem pump coupling has proper seating in camshaft.
• Tandem pump gasket must always be replaced.
- Install the tandem pump and tighten the upper bolts to 20 Nm.
- Tighten the lower bolts to 10 Nm.
- Connect the return hose (blue marking) to the return connection - 3 - on the tandem pump.
- Connect the supply hose (white marking) to supply connection - 2 - and the vacuum line from the brake booster - 1 - to the tandem pump - 4 -.
- Connect the supply hose (white marking) to the fuel filter.
- Connect the diesel extractor (VAS 5226) or the hand vacuum pump to the draining container (V.A.G 1390/1) on the return hose - 2 -.
- Operate the diesel extractor (VAS 5226) or the hand vacuum pump, until fuel comes out of the return hose. Make sure no fuel gets into the hand vacuum pump.
- Connect the return hose (blue marking) to the fuel filter.