Removing and installing vacuum pump (4.0 ltr. TDI): Audi A8 D3

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Renewed: hose clip onto vacuum hose

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• Take care not to damage the vacuum hose. The vacuum hose must be renewed if it is damaged. — Remove bolts (2) and (3).
• Renew O-ringsSecure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.
• On some models the vacuum hose has to be secured at the vacuum pump with a bolt.

🔩 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. Carefully pull engine cover panel off four mounting studs (one at a time) (arrows).
2. Remove cover for suspension turret (right-side); to do so, detach fasteners(1) and unscrew retainer (2).
3. Pull cover out of retainer clamps (arrows).
4. ⚠ Observe rules for cleanliness when working on the injection system. — Disconnect fuel return line (1) and fuel supply line (2) at fuel filter.
5. Unplug electrical connector (arrow) at fuel temperature sender G81 and move fuel lines to one side.

6. Disconnect vacuum hose (1) from vacuum pump.
7. ⚠ Take care not to damage the vacuum hose. The vacuum hose must be renewed if it is damaged. — Remove bolts (2) and (3).
8. Take off vacuum pump. [Note: Renew O-ringsSecure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.]
9. Set drive lugs of vacuum pump so they engage in slots in camshaft when vacuum pump is installed.
10. Attach vacuum pump to flange and tighten bolts to 9 Nm. — 9 Nm (6.6 lb-ft)
11. Fit new hose clip onto vacuum hose.
12. Push vacuum hose (1) onto connection on vacuum pump.
13. Fasten hose clip using suitable pliers. [Note: On some models the vacuum hose has to be secured at the vacuum pump with a bolt.]

Other AUDI procedures

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