Volkswagen Golf / Golf Plus. Manual - part 327

 

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Volkswagen Golf / Golf Plus. Manual - part 327

 

 

Note

The tandem pump must be checked for internal leaks between

fuel side and oil side after reinstalling a used tandem pump, for

example after renewing or repairing a cylinder head and/or when

installing a "short" engine. When leaking it is possible for the fuel

to mix with the oil which may cause the engine to fail.

Special tools and workshop equipment required
♦ Tester -V.A.G 1687-

Procedure
– Pull fuel supply hose (white marking) and fuel return hose

(blue marking) off tandem pump.

– Seal fuel return union on tandem pump with a plug. Secure

sealing plug with a spring-type clamp.

Prepare test unit -V.A.G 1687- as follows:
– Unscrew pressure regulating valve -2- and close valves -3-

and -4-.

– Connect test connection -5- to fuel supply union of tandem

pump using a commercially available compressed air connec‐

tion and a section of fuel hose. Use a spring-type clamp to

secure.

Note

To turn the pressure regulating valve -2- the knob must be pulled

upwards.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

146

     Rep. Gr.20 - Fuel supply system

 

Note

If there is water in the sight glass, drain at water drain screw -6-.

– Open valve -3-.
– Adjust pressure to 1.0 bar with pressure regulating valve -2-.

Caution

The maximum test pressure is 1.3 bar and this must not be

exceeded.

– Open valve -4- and wait until the test circuit is filled. If neces‐

sary readjust pressure to 1.0 bar.

– Close valve -3- to retain pressure and observe the pressure

drop over a period of 1 minute.

If the pressure does not drop the tandem pump can be reused, if

the pressure drops the tandem pump must be renewed.

5.5

Removing and installing tandem pump

DANGER!

The tandem pump may, under no circumstances, be disman‐

tled  as  the  vacuum  part  could  otherwise  malfunction.  This

would result in the failure of the brake servo.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

5. Repairing fuel supply system    

147

 

1331-

♦ Hand vacuum pump with

accessories -V.A.G 1390-

♦ Water drainage container -

V.A.G 1390/1-

♦ Spring-type clip pliers -VAS

5024 A-

5.5.1

Removing

– Pull supply hose (white marking) and return hose (blue mark‐

ing) off fuel filter.

– Connect hand vacuum pump with accessories -V.A.G 1390-

and water drainage container -V.A.G 1390/1- to return hose

-2-.

– Operate hand vacuum pump until no more fuel comes out of

return hose. Be careful that no fuel is sucked into hand vacuum

pump.

– Remove air filter housing with air mass meter and connecting

pipe.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

148

     Rep. Gr.20 - Fuel supply system

 

– Pull vacuum line from brake servo -1- off tandem pump -4-.
– Pull supply hose -2- (white marking) and return hose -3- (blue

marking) off tandem pump -4-.

– Remove securing bolts -arrows-.
– Remove tandem pump -4- from cylinder head.

5.5.2

Installing

Installation is carried out in the reverse order. When installing,

note the following:

Note

Ensure that tandem pump coupling seats properly in cam‐

shaft.

Always renew tandem pump seals.

– Install tandem pump and tighten upper securing bolts to

20 Nm.

– Tighten lower securing bolts to 10 Nm.
– Attach return hose (blue marking) to return connection -3- of

tandem pump.

– Attach supply hose (white marking) to supply connection -2-

and vacuum hose from brake servo -1- to tandem pump -4-.

– Connect supply hose (white marking) to fuel filter.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

5. Repairing fuel supply system    

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