Removing and installing vane pump, 4-cylinder diesel engine — VW

Removing and installing vane pump, 4-cylinder diesel engine
Special tools and workshop equipment required
Drip tray for workshop hoist
VAS 6208
Hose clip pliers
V.A.G 1921
Counterhold
T10172
Set of plugs for engine
VAS 6122
Torque wrench
V.A.G 1331
Hose clamps, up to 25 mm
3094
Procedure
If fitted, remove noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Remove poly V-belt
Rep. gr.
13
Cylinder head, pulley end; Removing and installing poly V-belt
Note
Before removing poly V-belt, mark running direction. A used belt can break if it runs in the opposite direction. When installing belt, ensure that it is correctly seated in pulleys.
Vehicles with air conditioning
Detach air conditioner compressor from bracket and attach to body
Heating, air conditioning system
Rep. gr.
87
Air conditioner compressor; Removing and installing air conditioning compressor on bracket
.
Continuation for all vehicles
Remove poly V-belt pulley
1
. When loosening bolts
2
brace with
counter-hold
T10172
.
Position
drip tray for workshop hoist
VAS 6208
underneath vane pump.
Clamp off suction hose
1
at vane pump with
hose clamps, up to 25 mm
3094
2
.
Loosen clip
3
using
hose clip pliers
V.A.G 1921
. Detach hose
1
from nozzle
4
.
Seal suction hose with a suitable plug from
engine plug set
VAS 6122
.
Unscrew bolts of pressure line
1
and remove pressure line from vane pump
2
.
Seal pressure line with a suitable plug from
engine plug set
VAS 6122
.
Remove bolt
3
.
Unscrew bolts
1
of vane pump
2
.
Remove vane pump
2
from bracket
3
.
Unscrew bolt of bumper cover
3
.
Remove coolant hose
1
from plastic bracket
2
and pull coolant hose away to side.
Swing vane pump
4
out forwards over cross-member. Pull bumper cover
5
forwards slightly as you do so.
To prepare for installation, press spacer
1
back until flush with bracket
2
.
Installing
Installation is performed in reverse sequence; note the following:
Note
Always remove seals and oil seals.
Before installing a new vane pump, fill with hydraulic oil on suction side. Turn vane pump by hand until hydraulic oil exits from pressure side.
Swing vane pump in from below over front cross-member.
Insert vane pump
7
into bracket
1
. Fit bolts by hand.
Pay attention to tightening sequence of securing bolts:
First tighten vane pump bolts
8
.
Then tighten vane pump bolts
3
.
Fit pressure line
2
with new seal
Item
.
Note
Make sure that pressure line
2
is pressed fully into block connection of vane pump.
Fit suction hose
5
to connection of vane pump
6
. When installing, make sure that markings
arrow
align.
Fit spring-type clip
Item
using
hose clip pliers
V.A.G 1921
in marked area.
Loosen
hose clamps, up to 25 mm
3094
on suction hose
5
.
Install poly V-belt pulley
1
and tighten bolts
2
. When doing this, brace using
counter-hold
T10172
.
Install poly V-belt for vane pump
Rep. gr.
13
Cylinder block, pulley end; Removing and installing poly V-belt
.
Top up hydraulic fluid if necessary. Allocation
Electronic Parts Catalogue
Bleed steering system and check for leaks
Chapter
.
Check fluid level in steering system and top up, if necessary
Chapter
or
Chapter
.
Specified torques
Chapter
“
Assembly overview - vane pump, 4-cylinder diesel engine
”
Noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Air conditioner compressor
Heating, air conditioning system
Rep. gr.
87
Air conditioning compressor; Removing and installing air conditioning compressor on bracket