Volkswagen Workshop Service and Repair Manuals

Removing and installing tandem pump   DANGER! The tandem pump may, under no circumstances, be dismantled as the vacuum part could otherwise malfunction. This would result in the failure of the brake servo.

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Hand-operated vacuum pump with accessories -V.A.G 1390-

t	Water drainage container -V.A.G 1390/1-

t	Spring-type clip pliers -VAS 5024 A-

Removing –  Remove engine cover. → Fig.

–  Remove bolt -arrow- and pull air filter housing upwards out of mounting. –  Remove air filter housing together with air mass meter and connecting pipe.

–  Pull off supply hose -1- (white marking) and return hose -2- (blue marking) from fuel filter. –  Connect hand vacuum pump with accessories -V.A.G 1390- and water drainage container -V.A.G 1390/1- to return hose -2-. –  Operate hand vacuum pump until no more fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump.

–  Pull vacuum line from brake servo -1- off tandem pump -4-. –  Pull supply hose -2- (white marking) and return hose -3- (blue marking) off tandem pump -4-. –  Remove securing bolts -arrows-. –  Remove tandem pump -4- from cylinder head. Installing Installation is carried out in reverse order, note the following:   Note t  Ensure that tandem pump coupling seats properly in camshaft. t  Always renew tandem pump seals. –  Install tandem pump and tighten top securing bolts to 20 Nm. –  Tighten bottom securing bolts to 10 Nm.

–  Attach return hose (blue marking) to return connection -3- of tandem pump. –  Attach supply hose (white marking) to supply connection -2- and vacuum hose from brake servo -1- to tandem pump -4-.

–  Attach supply hose -1- (white marking) to fuel filter. –  Connect hand vacuum pump with accessories -V.A.G 1390- and water drainage container -V.A.G 1390/1- to return hose -2-. –  Operate hand vacuum pump -V.A.G 1390- until fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump. –  Attach return hose (blue marking) to fuel filter.