Removal and Replacement

Tandem pump, removing and installing

Caution:
^ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
^ The fuel system is also under pressure! Before opening the system, place cloths around the connection. Then carefully loosen the connection to release the pressure.
^ Wear eye and hand protection when performing any type of repair work on the fuel system!

Special tools, testers and auxiliary items required





^ Torque wrench (5 ... 50 Nm) V.A.G. 1331
^ Hand vacuum pump V.A.G. 1390
^ Bleed container V.A.G. 1390/1
^ Spring-type clip pliers V.A.G. 1921

Removing





- Pull off supply hose - 1 - (white marking) and return hose 2 - (blue marking) from fuel filter.
- Connect hand vacuum pump V.A.G. 1390 with bleed container V.A.G. 1390/1 to return hose.





- Operate hand vacuum pump until no more fuel comes out of return hose. Ensure that no fuel is drawn into hand vacuum pump.
- Pull vacuum hose - 1 - from brake servo off tandem pump 4-.
- Pull supply hose - 2 - (white marking) off tandem pump - 4
- Remove securing bolts - arrows -
- Remove tandem pump - 4 - from cylinder head.
- Pull tandem pump - 4 - slightly upward, pull off return hose 3 - (blue marking) and remove tandem pump - 4

Installing
Installation is performed in the reverse order. When installing, note the following:





Note:
^ Ensure proper seating of tandem pump coupling in camshaft.
^ Always replace tandem pump seals.

- Connect return hose - 3 - (blue marking) to return connection of tandem pump.
- Install tandem pump and tighten upper securing bolts to 20 Nm.
- Tighten lower securing bolts to 10 Nm.





- Connect supply hose - 2 - (white marking) to supply connection of tandem pump and vacuum hose - 1 - from brake servo to tandem pump - 4 -.
- Connect supply hose - 1 - (white marking) to fuel filter.
- Connect hand vacuum pump V.A.G. 1390 with bleed container V.A.G. 1390/1 to return hose - 2 - (blue marking) of fuel filter.
- Operate hand vacuum pump until fuel comes out of return hose. Ensure that no fuel is drawn into hand vacuum pump.
- Connect return hose - 2 - (blue marking) to fuel filter.