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I noticed last weekend that the cover of my tandem fuel pump had started to leak diesel from the gasket.
I've put together a quick guide on how I've mananged to fix the problem for the Golf TDi 130 engine, but this still might be the same for other models.
1. Remove the entire air box and hoses (mainly for ease of access to the pump)
2. disconnect the fuel return (blue ringed) hose from the fuel filter.
3. disconnect the fuel send (white ringed) hose from the fuel filter.
At this point you might be able to force air down the fuel send pipe to empty the tandem pump of diesel out of the disconnected return pipe.
4. Remove the covering bolts from the pump and carefully remove the cover (fuel will spill out at this point), also the gasket might tear if its stuck to both surfaces so be careful.
You will be left with the following : http://jacktooth.com/golf/PC060069.JPG
The removed gasket and cover looks like this: http://jacktooth.com/golf/PC060070.JPG
5. Try again now to force air down the fuel send pipe to clear any fuel left in the pipe as this will drip into the pump and spoil the seal that is going to be applied.
6. Remove any traces of diesel left in the bottom of the pump with a cloth.
7. Completely de-grease the gasket groove and pump cover.
8. apply a bead of non-hardening blue gasket sealant into the groove and smooth round with a finger. Insert the gasket back on top of the sealant and slightly press into the groove.
9. Clear any excess sealant on the inner side of the gasket, you should now be left with something similar to this: http://jacktooth.com/golf/PC060071.JPG
10. Replace the cover and lightly tighten the cover bolts till hand tight in a diagonal pattern.
11. Wait a couple of minutes and then tighten again in a diagonal pattern.
12. At this point I removed the cover again and removed any excess sealant that had seeped onto the inner side of the gasket.
13. Replace the hoses and air box. (Haynes recommends using a vacuum pump to draw the fuel back into the tandem pump at this point, however I tried using one and couldnt draw any fuel through, it still started up fine after a couple of cranks)
Hope this helps someone with a similar problem as I couldn't find any guides on how to do this, all seemed to say replace the entire pump.
P.S. Stiati ca in USA a fost o actiune de rechemare in service a unor modele de VW cu probleme la pompa tandem? Nu as strica sa va verificati VIN in documentul atasat... poate VW trimite o pompa noua
Edited by C o s m i n, 28.03.2011 @ 08:06.