Audi Workshop Service and Repair Manuals

Removing and installing tandem pump - vehicles with 2.0 ltr. 4V engine Special tools and workshop equipment required

t  Hose clip pliers -V.A.G 1921-

t  Diesel suction pump -VAS 5226-

Removing Observe rules for cleanliness → Chapter. –  Pull off engine cover panel -arrows-.   WARNING t  The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles.

–  Detach vacuum hose -1- (going to brake servo) from tandem pump. –  Mark the installation position of fuel hoses. –  Detach fuel supply hose -2- and fuel return hose -3- from tandem pump.

–  Connect compressed air line to diesel suction pump -VAS 5226-. –  Connect diesel suction pump -VAS 5226- to fuel return connection on tandem pump.   Note t  You can also use hand-operated vacuum pump -V.A.G 1390- with bleeder container -V.A.G 1390/1- instead of diesel suction pump -VAS 5226-. t  Empty the bleeder container before it becomes full. Do not allow fuel to enter hand-operated vacuum pump. –  Operate diesel suction pump -VAS 5226- until no more fuel comes out of return connection.

–  Remove bolts -arrows-.   Note Illustration shows tandem pump with engine removed from vehicle. –  Remove tandem pump from cylinder head. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew tandem pump gaskets. t  Ensure proper seating of tandem pump actuator in camshaft. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install tandem pump and tighten the flange bolts -arrows-.

–  Attach fuel supply hose -2- (white marking) and fuel return hose -3- (blue marking) to tandem pump according to markings. –  Attach vacuum hose -1- (going to brake servo) to tandem pump. Tightening torque

Component	Nm
Tandem pump to cylinder head	20