Tandem and Fuel Pump

Tandem and Fuel Pump


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.

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Spring Type Clip Pliers (VAS 5024 A)

Removing

• The procedure for removing and installing tandem pump is described. The procedure for the fuel pump is identical up to disconnecting the vacuum line.

Vehicles with Engine Code BKW:

- Remove the fuel filter. Refer to => [ Fuel Filter ] Removal and Replacement.

Vehicles with Engine Code BWF:

- Remove the bypass flap with cooler for Exhaust Gas Recirculation (EGR). Refer to => [ Bypass Flap with Cooler for EGR ] Bypass Flap with Cooler for EGR.

Continuation for all Vehicles:

- Remove the intake manifold. Refer to => [ Intake Manifold ] Service and Repair.

- Disconnect the vacuum line - 1 - from the tandem pump - 5 -.






- Disconnect the central connector for pump injector units - 3 -.

- Disconnect the fuel hose - 2 - from the tandem pump - 5 -.

- Remove the bolts - arrows -.

- Remove the tandem pump - 5 - from the cylinder head.

- Pull the tandem pump - 5 - slightly upward, unscrew the fuel hose - 4 - and remove the tandem pump.

Installing

Installation is performed in the reverse order of removal, noting the following:

• Make sure that tandem pump coupling has proper seating in the camshaft.

• The tandem pump seals must always be replaced.

- Connect the fuel line - 4 - with new seals to the tandem pump - 5 - and tighten the banjo bolt to 25 Nm.






- Install the tandem pump and tighten the bolts - arrows -.

Tightening specification:

• M6 bolts - 8 Nm

• M8 bolt - 20 Nm

- Connect the fuel hose - 2 - and vacuum line - 1 - to the tandem pump.

- Connect the central connector for the pump injector units.

Vehicles with Engine Code BKW:

- Install the fuel filter. Refer to => [ Fuel Filter ] Removal and Replacement.

Vehicles with Engine Code BWF:

- Install the bypass flap with cooler for EGR. Refer to => [ Bypass Flap with Cooler for EGR ] Bypass Flap with Cooler for EGR.

Continuation for all Vehicles:

- Install the intake manifold. Refer to => [ Intake Manifold ] Service and Repair.

- Perform a test drive and check the Diagnostic Trouble Code (DTC) memory. Refer to => [ Engine Control Module DTC Memory, Checking and Erasing ] Scan Tool Testing and Procedures.

• By disconnecting the central connection for the pump injector unit, DTCs will be stored. Query the fault memory and erase, if necessary.