Tandem Pump: Removing

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Read safety precautions before beginning work FUEL SUPPLY SYSTEM SAFETY PRECAUTIONS .

Observe the rules for cleanliness CLEAN WORKING CONDITIONS .

-- Turn the ignition and all electrical consumers off and remove the ignition key.

-- Remove engine cover.

One Piece Engine Cover

Fig 1: Identifying Removal Of One Piece Engine Cover

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Pull the one piece front engine cover -arrows A- upward with a quick jerk and then pull the lower mount -arrow B- forward.

Two Piece Engine Cover

Fig 2: Identifying Removal Of Two Piece Engine Cover

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On the two piece engine cover, first pull the outer cover upward with a quick jerk -arrows in the upper illustration-, then pull the inner engine cover upward with a quick jerk -arrows in lower illustration-.

-- Disconnect electrical harness connector -2- at Mass Air Flow (MAF) sensor -G70-.

Fig 3: Identifying Ventilation Hose -1-, Electrical Harness Connector -2-, Spring-Type Clip -3-, Bolt -4- And Intake Manifold -5-

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-- Disconnect the ventilation hose -1- and disengage it from the bracket -arrow-.

-- Open the spring-type clip -3- using spring-type clip pliers VAS 5024A and disconnect the intake hose from the Mass Air Flow (MAF) sensor -G70-.

-- Disconnect the intake manifold -5- from the air guide.

-- Unfasten bolt -4- and remove air filter housing and mass air flow sensor.

-- Carefully cut the cable tie -1-.

Fig 4: Identifying Cable Tie And Wiring Bracket

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-- Open the wiring bracket -2- and disengage the wiring harness.

-- Remove both bolts -arrows- from the upper charge air pipe -A-.

Fig 5: Identifying Bolts -Arrows- From Upper Charge Air Pipe -A-

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-- Remove noise insulation Removal and Installation .

-- Remove the charge air pipe bolt -arrow- -A- from the oil pan.

WARNING:

The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Wear protective goggles and protective gloves when working on the fuel system!

-- Pull off the supply hose (white marking) and the return hose (blue marking) from the fuel filter.

-- Connect the diesel extractor VAS 5226 or the hand vacuum pump to the draining container V.A.G 1390/1 on the return hose -2-.

Fig 6: Identifying Hand Vacuum Pump V.A.G 1390 And Draining Reservoir V.A.G 1390/1 Connected To Return Hose

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-- Operate the diesel extractor VAS 5226 or the hand vacuum pump, until fuel stops coming our of the return hose. Make sure no fuel gets into the hand vacuum pump.

-- Disconnect vacuum line of brake booster -1- from tandem pump -4-.

Fig 7: Identifying Brake Booster Vacuum Line, Tandem Pump, Supply Hose & Return Hose

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-- Disconnect supply hose -2- (white marking) and return hose -3- (blue marking) from tandem pump -4-.

-- Remove mounting bolts -arrows-.

-- Remove tandem pump -4- from cylinder head.