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.