Jetta L4-1.9L DSL Turbo (BEW) (2004)
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Use special clic-hose clip pliers V.A.G 1723 to remove clamp and vacuum hose -1- from tandem pump -4-
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Use special spring clamp pliers to remove clamp and fuel supply hose -2- with white mark from tandem pump
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Remove 6mm socket head bolts -arrow A- and 5mm socket head bolts -arrow B- securing tandem pump to cylinder head
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Separate tandem pump from cylinder head
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Raise tandem pump slightly upward, remove clamp and fuel return hose -3- with blue mark and remove tandem pump
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Remove seal if it was not removed with tandem pump
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Clean rear surface of cylinder head in preparation for new tandem pump installation
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Proceed to Section G
Section G
Section G - New Beetle Vacuum Pump Installation
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On new tandem pump (038 145 209 E) connect fuel return hose -3- with blue mark to return connection of tandem pump -4- and secure with
spring clamp
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Ensure coupling is properly aligned to the camshaft, install tandem pump and secure with socket head bolts -arrow A- and -arrow B-
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Tighten upper 6mm socket head bolts -arrow A- to 20 Nm (15 ft. lbs.) and lower 5mm socket head bolts -arrow B- to 10 Nm (7 ft. lbs.)
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Connect fuel supply hose -2- with white mark to fuel supply connection of tandem pump and secure with spring clamp
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Connect vacuum hose -1- to tandem pump and secure with clamp
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Connect fuel supply hose -1- with white mark to fuel pipe and secure with spring clamp
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Connect suction pump VAS 5226 to fuel return pipe -3-
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Operate suction pump until fuel comes out of fuel return pipe
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Disconnect VAS 5226 from the fuel return pipe and connect fuel return hose -2- with blue mark to fuel return pipe and secure with spring clamp
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If removed, reconnect connector to center glow plug
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Reinstall upper air filter with connecting hose
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Reconnect vacuum hose to upper air filter
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Reinstall flexible connection hose between air flow sensor and air pipe and secure with spring clamps
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Reconnect connector to mass air flow sensor