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    Thread: Suction pump DIY **w/ pix**

    1. Member Slimjimmn's Avatar
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      07-28-2011 03:09 PM #1
      I haven't seen any writeups on replacing a suction pump on a 1.8t so here goes.

      I was having some issues with cold start misfires. Then I was getting limp mode and check engine light no more than 5psi. Codes were for cyl 1/2 misfires, random misfires, system too lean, turbo throttle valve pressure drop. I have new coils, plugs, all new pcv system, no vacuum leaks I can find. At idle I had 16-18" vacuum and when you depress the brake pedal a couple times it would stumble some. Anyway, went to VW and bought the new "D" style suction pump and some extra hoses attached to it.
      058-133-753D pump
      06A-133-784P "c" shaped hose
      06A-133-783AS other hose that goes to intake
      you will need plenty of hose clamps so make sure you have the right sized ones.

      Just a note, the pump should not have pressure blown through it and have pressure come out both nipples at the same time, only one nipple should have pressure come out. If both come out it has failed internally.

      First take off engine covers if you have them. Next remove the 2 10mm nuts that hold the secondary air hose to the valve bracket and unclip hose and pull to the side next to throttle body. Next remove the 10mm nut that holds the other secondary air hose to the underside of the valve bracket, its right in the middle.

      pic of the hose with the 10mm nut you take off


      Next remove the 2 5mm allen bolts that hold the bracket to the intake manifold and pull up and away to separate it from the dipstick funnel. Unplug the solenoid here. (note this is a good time to replace the dipstick funnel if its broken, which it most likely is)


      Next pull the bracket to the side and pull the small vacuum hose off the intake nipple.


      Remove the pcv hose from the nipple and push aside. The suction pump is there, the "y" thing.


      Next up top, cut off this hose clamp and pull the hose out, it will be stuck a little, it holds vacuum in the brake booster.


      Next under the intake remove the hose from the other side of the dipstick funnel, this hose goes to the suction pump. Also remove this hose and clamp, it goes to the smaller port on the "y" part of the pump.


      The assembly should be fully loose now, so just fenangle it out, usually the last part out is the big plastic hose that goes through the intake manifold runners. Once out it looks like this.


      New one assembled.


      Once all the new stuff is together make sure the angles and what not are the same or it will flex the rubber hoses too much and fail prematurely. Install is the same as removal, just use new clamps and you will be good to go.
      After installing my vacuum at idle is now 20" when cold. Turbo spools a little quicker and it seems to hold boost better. I put my ecs n75 race valve back in and still need to test drive it. I know I need new boost hoses and a silicone TIP to be good to go, but I also need front brakes, downpipe (thats cracked) and full exhaust.
      Last edited by Slimjimmn; 08-16-2011 at 11:24 PM.
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    2. 08-04-2011 12:04 PM #2
      Do you have a pic of the failure point?

      Thanks
      Last edited by manyDUBs; 08-04-2011 at 12:11 PM.

    3. Member l88m22vette's Avatar
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      08-04-2011 02:29 PM #3
      Here is how I fixed mine



      Seriously though, nice write-up
      Audi TT mk1 FAQ zero Porsche wheels given

      Quote Originally Posted by jackboots View Post
      Torque is how many crubs and briks you can sled into. Horsepower is how fast you can sled into them, multiplied by how load your cam knock is.

    4. Member Slimjimmn's Avatar
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      08-04-2011 10:05 PM #4
      Quote Originally Posted by manyDUBs View Post
      Do you have a pic of the failure point?

      Thanks
      it failed internally. It would not hold vacuum.
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    5. Member Dub Ken's Avatar
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      08-04-2011 11:15 PM #5
      I thought it was standard procedure to shítcan emissions stuff in this forum when they fail.

      Great info for those looking to keep a factory-built engine.

    6. Member travis_gli's Avatar
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      08-05-2011 10:44 AM #6
      Quote Originally Posted by Dub Ken View Post
      I thought it was standard procedure to shítcan emissions stuff in this forum when they fail.

      Great info for those looking to keep a factory-built engine.
      When you're in a state that won't allow you to pass emissions unless this stuff is present it doesn't work that way. Good write up!

    7. Member l88m22vette's Avatar
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      08-05-2011 02:18 PM #7
      ^ The only way they know is by having a CEL, no way an inspection agent is going to go hunting around for specific pieces in the dozens of types of cars out there...
      Audi TT mk1 FAQ zero Porsche wheels given

      Quote Originally Posted by jackboots View Post
      Torque is how many crubs and briks you can sled into. Horsepower is how fast you can sled into them, multiplied by how load your cam knock is.

    8. Member travis_gli's Avatar
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      08-05-2011 02:24 PM #8
      Quote Originally Posted by l88m22vette View Post
      ^ The only way they know is by having a CEL, no way an inspection agent is going to go hunting around for specific pieces in the dozens of types of cars out there...
      The inspection machine checks for readiness. So no they don't just look for a CEL.

    9. Member Slimjimmn's Avatar
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      08-05-2011 11:31 PM #9
      And if u live in pa, they do safety inspections
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    10. Member Levi20AE's Avatar
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      08-06-2011 11:48 AM #10
      I have a Uni MAFless file with all the readiness codes set and the suction pump is causing a boost leak when I charge the system to ~20psi with a leak tester. When you remove the suction pump are you putting a T in it's place or what other plumbing are you removing along with it? I don't have a problem passing a visual inspection and the software takes care of the rest.

    11. Member Slimjimmn's Avatar
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      08-07-2011 12:57 AM #11
      if you were to delete the pump, just put inline a vacuum T at that point, but I dont know where you can find such a large T, its about 1/2" i think
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    12. Member Dub Ken's Avatar
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      08-07-2011 03:08 PM #12
      Quote Originally Posted by travis_gli View Post
      The inspection machine checks for readiness. So no they don't just look for a CEL.
      Easily remedied with software edit which forces readiness.

    13. Member Slimjimmn's Avatar
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      08-07-2011 11:36 PM #13
      Quote Originally Posted by Dub Ken View Post
      Easily remedied with software edit which forces readiness.
      or slip the tester a 50 and your golden...
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    14. Member boostingti4ever's Avatar
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      08-08-2011 08:16 AM #14
      Quote Originally Posted by Slimjimmn View Post
      or slip the tester a 50 and your golden...
      this^ only thing that passes readiness is a/c
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      08-08-2011 08:31 AM #15
      good write-up

    16. 08-12-2011 01:22 PM #16
      I removed mine and now I get a CEL

    17. Member travis_gli's Avatar
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      08-12-2011 01:35 PM #17
      Quote Originally Posted by boostingti4ever View Post
      this^ only thing that passes readiness is a/c
      from my understanding those results get sent in to the state... so I'm not sure how he's slipping you stickers.

      Quote Originally Posted by manyDUBs View Post
      I removed mine and now I get a CEL
      Improper flow? If so there's not much you can do unless you get it coded out of the ECU. While your doing that you might as well get the readiness monitors coded as well. Only problem with all that is if your using an APR ecu or another software vendor that encrypts their software whoever is attempting to code everything out may not be able to.

    18. Member Slimjimmn's Avatar
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      08-16-2011 11:25 PM #18
      on a side note, use the right f-en hoses. I bought the incorrect hose that goes to the intake manifold "h" and the correct one was "as". Took about 2 weeks of driving for the hose to break off and make my car run like poo.
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    19. 08-20-2011 11:32 AM #19
      Hi guys, i have and 1.8T 25th anniv engine code AUQ, and i purchased a new suction pump by the reference that is in the post (058-133-753D), but searching in ETKA i've noticed that for my engine the suction pump part number are diferent than the current on this post (for AUQ engine code: 06A-133-751AE), can any one tell me diferences in them?

      If i install the one that is in the thread will work fine, or i have to change it with a new one?

    20. Member Slimjimmn's Avatar
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      08-23-2011 12:51 AM #20
      Post a pic
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    21. Junior Member
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      12-24-2011 06:15 AM #21
      Why not replace only the suction pump and keep the original hoses?

    22. Member Slimjimmn's Avatar
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      12-26-2011 11:42 PM #22
      they were all rotted out and cracked anyway

      contemplating a catch can setup and ditching the whole pcv setup now.
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    23. Junior Member
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      12-27-2011 04:59 AM #23
      Quote Originally Posted by Slimjimmn View Post
      they were all rotted out and cracked anyway

      contemplating a catch can setup and ditching the whole pcv setup now.
      What are the benefits of a catch can setup vs the pcv?

    24. Member Slimjimmn's Avatar
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      12-27-2011 10:18 PM #24
      pcv oil and vapor goes into catch can, not the intake/intercooler. Only downside is in colder climates, if the can isnt emptied say weekly, sometimes the water vapor separates and freezes then when you start your car- Kapoweeeeee, can blows up lol

      Plus its hard to find a spot to install one on a mk4 that is easy to service.
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    25. Member Slimjimmn's Avatar
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      06-10-2012 10:58 PM #25
      bump, because I see so many people asking questions every week on pcv stuff
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    26. Junior Member
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      06-10-2012 11:44 PM #26
      Car is on stands now and i.m in the middle of deleting everything except the PCV. Just waiting for SAI Plate and resistors from IE.

    27. Member Slimjimmn's Avatar
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      06-11-2012 10:06 PM #27
      for IE. I got my plate from them along with the resistor plugs


      for keeping the pcv
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    28. Member Slimjimmn's Avatar
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      01-31-2013 10:55 PM #28
      bumpski
      no FAQ yet?
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    29. 02-01-2013 06:14 AM #29
      What system would that that effect readiness wise?
      Quote Originally Posted by Marcus_Aurelius View Post
      If you're going to come like this, why don't you come correct? I think you mean Samuel Langhorne Clemens. What's next, you want the work cited to be mentioned as well, on a car forum sig in quotation? How about you fail me professor

    30. Member Slimjimmn's Avatar
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      02-01-2013 08:10 AM #30
      Quote Originally Posted by Twopnt016v View Post
      What system would that that effect readiness wise?
      None.
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    31. Member
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      02-01-2013 12:28 PM #31
      In short, do not use catch can to avoid weekly clean up.

      Quote Originally Posted by Slimjimmn View Post
      pcv oil and vapor goes into catch can, not the intake/intercooler. Only downside is in colder climates, if the can isnt emptied say weekly, sometimes the water vapor separates and freezes then when you start your car- Kapoweeeeee, can blows up lol

      Plus its hard to find a spot to install one on a mk4 that is easy to service.

    32. Member Shamrock's Avatar
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      02-03-2013 06:05 PM #32
      Quote Originally Posted by travis_gli View Post
      from my understanding those results get sent in to the state... so I'm not sure how he's slipping you stickers.



      Improper flow? If so there's not much you can do unless you get it coded out of the ECU. While your doing that you might as well get the readiness monitors coded as well. Only problem with all that is if your using an APR ecu or another software vendor that encrypts their software whoever is attempting to code everything out may not be able to.
      Maestro Works for me

    33. Junior Member tupi23dna's Avatar
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      08-10-2013 05:33 PM #33
      This write up saved me!!!! I thought I was gonna have rip off the IM. Thank you! !!!

    34. Member Slimjimmn's Avatar
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      08-11-2013 01:14 PM #34
      just trying to help
      the car is on an inclined driveway and up on jack stands in the front only
      02 GTI 1.8t:> 42DD 3" turboback, BFI full stg1 mount kit, Evoms CAI, Forge boost hoses, Tacotaco sidemount, Ebay TIP, IE 2.0 coil conversion, IE manual tensioner, 20th front brake conversion, IE emissions delete, 42dd catch can, Koni STR.t & WRD sport springs, Samco Coolant hoses, SMF vr6 clutch kit.

    35. Moderator groggory's Avatar
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      08-12-2013 02:41 PM #35
      FAQ'd
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

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