Exploded view - vacuum pump, vehicles with 1.8-l TSI and 2.0-l TSI engines

Note The vacuum pump is driven mechanically.

1. - High-pressure pump
   • Removing and installing
2. - Bolt
   • Tightening torque
3. - O-ring
4. - Seal
   • Renew
5. - Coolant pipe
6. - Bolt
   • 9 Nm
7. - Vacuum line
   • Replace if damaged
8. - Vacuum line
   • Replace if damaged
9. - Bolt
   • Specified torque: 9 Nm.
10. - Manual vacuum pump

Removing and installing vacuum pump, vehicles with 1.8-l TSI and 2.0-l TSI engines

Removing:

• Remove the high-pressure pump.
• Screw the bolt -1- of the coolant line out.
• Disconnect the vacuum hoses -2 and 3- from the vacuum pump and lay to one side.

• Loosen and remove the screws of -arrows- vacuum pressure pump -2-.
• Lift the coolant line -1- up and remove the vacuum pump out of its seat.

Installation:

Carry out installation in the reverse sequence, noting the following:

Note Renew seal.

• Ensure that seal is seated correctly.
• Turn the drive lug of vacuum pump -1- so it engages in the slot in the camshaft when the vacuum pump is installed -arrows-.
• Install the high-pressure pump .

Removing and installing vacuum pump (vehicles with TDI engine)

Note The vacuum pump of the brake booster is installed in oil pump -1-.

• Removing and installing oil pump with vacuum pump.

Checking the retention valve

Test sequence

• Carefully pull non-return valve with vacuum line -1- out of brake booster.
• Blow small amount of air through non-return valve -1- in one direction first, then in other direction.
• Air must pass through non-return valve -1- in -direction of arrow-.
• The non-return valve -1- must remain closed in the opposite -direction of arrow-. If this is not the case, renew non-return valve or, if necessary, complete vacuum line.

Note When installing the vacuum line with non-return valve, ensure the correct installation position relative to the brake booster.

Removing and installing non-return valve

Note

• The non-return valve is fitted directly in front of the vacuum pump.
• The vacuum pump does not have to be removed.

Removing:

• Open the O-type clip on the vacuum hose with a suitable pair of pliers.
• Detach vacuum hose from vacuum pump for brakes - V192- .

• Pull the non-return valve out of the vacuum hose.

Installation:

• Place the non-return valve into the vacuum hose.

Note

• Pay attention to correct installation position.
• The arrow indicating the flow direction points towards the vacuum pump.
• To simplify fitting, lightly moisten the non-return valve and the vacuum hose with water but not with oil.

• Push a new O-type clip over the vacuum hose.