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TT (Mk1) Discussion Discussion forum for the Mk1 Audi TT Coupe & Roadster produced from 2000-2006

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Old 03-25-2007, 02:20 PM   #1
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Default PSA: check that secondary air injection pump!

You might be able to fix it in place, before it gets bad enough to require removing it...

While changing the oil today, I noticed that several of the rivets that hold the 2 halves of the air pump body together were in the process of disintegrating.



The heads had separated from the rivet body, probably from vibration when the pump runs, allowing the halves of the air pump to begin to separate. Three were shot. Here's a closeup



I pushed the rivets out of the housing by inserting a sheet metal screw from the broken side and pushing a bit... the rivets emerged from the other side enabling me to pry them out. The rivets are the same diameter as #8 screws. I found 1.5" stainless steel replacements at Home Desperate; they fit perfectly.



I was able to replace the 2 lower rivets... using a bit of Loc-tite. There's still a broken one but it's too hard to reach. Hopefully this will keep the pump body together, reducing stress on the other rivets. Here's a pic, once repaired.



Stupid cost-cutting measure... the screw & nut option would only cost a few cents more than the rivets during manufacture, but if the rivets fail, it costs like $400-600 in labor and parts to replace the air pump.

Anyway, take a peek next time you're poking around down there. Save the money for mods.

~john
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Old 03-25-2007, 02:24 PM   #2
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Default Full replacement of all of those rivets is one of my>>>

summer projects...after 125k miles...i am sure it is required...good post..
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Old 03-25-2007, 02:26 PM   #3
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Default Nice catch, and "grassroots" repair!

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Old 03-25-2007, 02:28 PM   #4
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Default Great find! Bookmarked.

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Old 03-25-2007, 02:41 PM   #5
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Default you'll only be able to access the bottom 3 with the pump in the car...

there is at least one more visible, maybe more on the top. Good luck with it.

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Old 03-25-2007, 03:52 PM   #6
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Default Yipes, I just changed my oil..... how many miles on your TT? I don't want to crawl under again.

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Old 03-25-2007, 04:04 PM   #7
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Default tight packaging strengthens the case for 10k oil drain intervals ;)

51k miles on my TT, all in the Chicago area (hence the salt stains on many of the underhood bit).

I don't know when the rivets started coming loose.. . although I had noticed the air pump seeming noiser this winter when starting up in the morning.
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Old 03-25-2007, 06:42 PM   #8
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Default Were you getting a CEL that referred to Secondary Air Injection?

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Old 03-25-2007, 11:10 PM   #9
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Default been there >>

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Old 03-26-2007, 03:49 AM   #10
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Default no CEL, but it was louder on startup... hoping to head off the CEL experience

my daughter's A4 has a persistent CEL that has been linked to the air injection system though, so that's the next patient I treat.
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Old 03-26-2007, 03:49 AM
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2003, a4, air, audi, b6, cost, fix, injection, primary, pump, removal, rivet, rivets, secondary, tt


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