Section G

Section G - New Beetle Vacuum Pump Installation





- On new tandem pump (038 145 209 E) connect fuel return hose -3- with blue mark to return connection of tandem pump -4- and secure with spring clamp
- Ensure coupling is properly aligned to the camshaft, install tandem pump and secure with socket head bolts -arrow A- and -arrow B-
- Tighten upper 6mm socket head bolts -arrow A- to 20 Nm (15 ft. lbs.) and lower 5mm socket head bolts -arrow B- to 10 Nm (7 ft. lbs.)
- Connect fuel supply hose -2- with white mark to fuel supply connection of tandem pump and secure with spring clamp
- Connect vacuum hose -1- to tandem pump and secure with clamp





- Connect fuel supply hose -1- with white mark to fuel pipe and secure with spring clamp
- Connect suction pump VAS 5226 to fuel return pipe -3-
- Operate suction pump until fuel comes out of fuel return pipe
- Disconnect VAS 5226 from the fuel return pipe and connect fuel return hose -2- with blue mark to fuel return pipe and secure with spring clamp
- If removed, reconnect connector to center glow plug
- Reinstall upper air filter with connecting hose
- Reconnect vacuum hose to upper air filter
- Reinstall flexible connection hose between air flow sensor and air pipe and secure with spring clamps
- Reconnect connector to mass air flow sensor
- Start engine and check for leaks
- Reinstall engine cover
- Place removed tandem pump in original shipping container from new tandem pump and return to Volkswagen Canada Inc; Parts Depot; Attn: Ron Bradshaw - VY Recall; 777 Bayly St. West; Ajax, ON Canada L1S 7G7
- Properly dispose of removed fluids