Removing and installing tandem pump - Audi S4/S6 with 5-cyl. turbo engine — AUDI

🧭 Before you start

Clamp and detach the coolant hose, remove the belt guard, slacken the pulley bolts, lock the tensioner and take the belt off after marking its direction. Clamp the hydraulic lines, disconnect and plug them, remove the suction hose and unbolt the pump. Fit the new pump at 25 Nm, transfer the suction union at 50 Nm, reconnect the lines and remove the clamps. Refit pulley and belt, release the mandrel, refit the guard carefully, reconnect the coolant hose and check belt alignment and coolant level.

Fits: platform code 4A

• Special tools named: 3094, 3093

Don't miss

• Mark the belt's running direction before removal; a used belt run backwards can be destroyed.
• Tandem pump to holder: 25 Nm. Suction hose union into the new pump: 50 Nm.
• Plug the open hydraulic ports straight away to keep dirt out.
• Fit the belt guard carefully so the pulley does not catch it.
• Check belt alignment and top up coolant after the job.

Written for this job from the workshop steps below · TorqFix editorial.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Pinch off the coolant hose with a hose clamp 3093 and detach.
2. Remove the belt guard.
3. Slacken off the pulley bolts; to do so, shorten the Allen key appropriately.
4. To slacken off the poly V-belt, press the open-ended wrench in (arrow direction).
5. Insert the mandrel3204 to secure. [Note: Mark the direction of the poly V-belt with chalk or a felt-tip pen prior to removal. Running a used belt in the opposite direction could destroy it. Pay attention to correct positioning on pulleys when fitting the belt.]

6. Detach the poly V-belt from the pulley.
7. Screw out the hexagon socket head bolts for the pulley and detach the pulley.
8. Pinch off the suction and return pipes with hose clamps 3094.
9. Unscrew the high-pressure hose and expansion hose from the pump.
10. Seal the connecting holes with plugs.
11. Unfasten the clamp and detach the suction hose.
12. Screw out the bolts (arrows).
13. Take out the tandem pump.
14. Insert the tandem pump in the holder and tighten the bolts to 25 Nm. — 25 Nm (18 lb-ft)
15. Screw the high-pressure hose and expansion hose to the pump.
16. Attach the suction hose to the screw connection and secure with a clamp. [Note: Screw the screw connection for the suction hose out of the defective tandem pump and screw into the new tandem pump (50 Nm).]
17. Detach the hose clamps 3094 from the suction and return hose.
18. Screw in the pulley and flange bolts by hand.
19. Carefully position the poly V-belt on the pulley and tension it; to do so, press the tensioner in (arrow direction) and take out the mandrel3204.
20. Use a shortened Allen key to tighten the pulley bolts.
21. Carefully install the belt guard to avoid damage caused by the pulley catching.
22. Attach the coolant hose to the connection piece at the engine block and secure with a clamp.
23. Remove the hose clamp 3093.
24. Check the alignment of the poly V-belt .
25. Check the coolant level and top up if necessary 401.

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