Audi Workshop Service and Repair Manuals

Removing and installing tandem pump - vehicles with 2-valve engine Special tools and workshop equipment required

t  Hose clip pliers -V.A.G 1921-

t  Diesel extractor -VAS 5226-

Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. Engine cover panel (version 1): –  Lift engine cover panel at the sides -arrows 1- and pull off towards the front -arrow 2-.

Engine cover panel (version 2): –  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

All vehicles (continued): –  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct (bottom) together with air hose.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.   WARNING t  The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection. t  In extreme cases the temperature of the fuel lines and the fuel can be up to 100 °C after the engine is switched off. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles.

–  Disconnect fuel supply hose -2- from tandem pump. –  Disconnect fuel return hose -1- (blue marking) from fuel pipe.

–  Connect compressed air line to diesel extractor -VAS 5226-. –  Connect diesel extractor -VAS 5226- to fuel return hose.   Note Empty the bleeder container before it becomes full. Do not allow fuel to enter hand vacuum pump. –  Operate diesel extractor -VAS 5226- until no more fuel comes out of return hose.

–  Detach vacuum hose -arrow- going to brake servo at tandem pump.

–  Remove bolts -arrows-. –  Remove tandem pump from cylinder head. Installing Installation is carried out in the reverse order; note the following:   Note t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Renew tandem pump gaskets. t  Ensure proper seating of tandem pump actuator in camshaft. –  Install tandem pump and tighten top securing bolts to 20 Nm. –  Tighten bottom securing bolts to 10 Nm. –  Connect all hoses to tandem pump.