Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1390 Vacuum pump
• ◆ V.A.G1390/1 Fluid receptacle
• ◆ VAS 5024 Assembly tool for spring-type clamps

Removing

• ‒ → Pull off supply hose -1- (white marking) and return hose -2- (blue marking) from fuel filter.
• ‒ Connect hand vacuum pump V.A.G 1390 with fluid receptacle V.A.G 1390/1 to return hose.
• ‒ 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 hose -1- from brake servo off tandem pump -4-.
• ‒ Pull off the central connector for the unit injectors.
• ‒ Pull supply hose -2- (white marking) off tandem pump -4-.
• ‒ Remove securing bolts -arrows-.
• ‒ Remove tandem pump -4- from cylinder head.

• ‒ → Pull tandem pump -4- slightly upwards, pull off return hose -3- (blue marking) and remove tandem pump -4-.

Installing

Installation is carried out in the reverse order, when doing this note the following:

Notes:

• ◆ Ensure proper seating of tandem pump coupling in camshaft.
• ◆ Always replace tandem pump seals.

• ‒ Attach return hose -3- (blue marking) to return connection of tandem pump.
• ‒ Install tandem pump and tighten upper securing bolts to
      20 Nm.
• ‒ Tighten lower securing bolts to
      10 Nm.
• ‒ Attach supply hose -2- (white marking) to supply connection of tandem pump and vacuum hose -1- from brake servo to tandem pump -4-.
• ‒ Connect central connector for unit injector connectors.

• ‒ → Attach supply hose -1- (white marking) to fuel filter.
• ‒ Attach hand vacuum pump V.A.G 1390 with fluid receptacle V.A.G 1390/1 to return hose -2- (blue marking) of fuel filter.
• ‒ Operate hand vacuum pump until fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump.
• ‒ Attach return hose -2- (blue marking) to fuel filter.
• ‒ Interrogate fault memory:

=> Repair group 01; Self-diagnosis; Interrogating and erasing fault memory

Note:

Faults are stored when the central connector for unit injectors is disconnected. Therefore interrogate and erase fault memory.