Removing and installing tandem pump, engine codes AXD, AXE, BLJ, BNZ, BPC — VW

Removing and installing tandem pump, engine codes AXD, AXE, BLJ, BNZ, BPC
Removing
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 booster.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Spring-type clip pliers
VAS 5024
Remove coolant expansion tank and place to one side (leaving hoses connected).
Remove charge air pipe between intake manifold and charge air cooler.
Detach vacuum line
1
of brake servo from tandem pump
4
.
Detach fuel line
2
from tandem pump
4
.
Unscrew fuel line
3
from tandem pump
4
.
Unscrew securing bolts
arrows
.
Remove tandem pump
4
from cylinder head.
Installing
Installation is carried out in the reverse order. When installing, note the following:
Note
Ensure that tandem pump coupling seats properly in shaft.
Always renew tandem pump seals.
Install tandem pump and tighten securing bolts
arrows
.
Perform leakage test
Chapter
.
Attach fuel hose
2
and vacuum hose
1
to tandem pump.
Connect fuel line
3
to tandem pump
4
, and tighten union nut to specified torque.
Connect
hand vacuum pump with accessories
V.A.G 1390
and
water drainage container
V.A.G 1390/1
to return hose
2
.
Note
On vehicles with no fuel pre-heating, separate return hose connection (blue marking)/return line (brown) next to fuel filter. Then, connect
hand vacuum pump with accessories
V.A.G 1390
and
water drainage container
V.A.G 1390/1
to return hose.
Operate
hand vacuum pump
V.A.G 1390
until fuel comes out of return hose. Make sure that no fuel is sucked into
hand vacuum pump
.
Reconnect return hose
2
(blue marking).
Install charge air pipe between intake manifold and charge air cooler.
Secure coolant expansion tank.
Note
The tandem pump must always be checked for internal leaks between fuel side and oil side after reinstalling a used tandem pump
Chapter
.
Carry out a road test, and read event memory
Vehicle diagnostic tester
; clear event memory of engine control unit.
Specified torques
Bolts securing tandem pump to cylinder head
Rep. gr.
15
Cylinder head; Assembly overview – cylinder head
Component
Specified torque
Union nut for securing fuel line to tandem pump
25 Nm