PSA: check that secondary air injection pump! - AudiWorld Forums

Go Back   AudiWorld Forums > Audi Models > Audi TT / TT-S / TT-RS > TT (Mk1) Discussion
Log In 


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

PSA: check that secondary air injection pump!

Reply
 
 
 
 
LinkBack Thread Tools Search this Thread
Old 03-25-2007, 02:20 PM   #1
AudiWorld Super User
 
Join Date: Nov 2003
Posts: 2,008
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
__________________
I'm outta here now...
jhoeppel is offline   Reply With Quote
Old 03-25-2007, 02:24 PM   #2
AudiWorld Super User
 
Join Date: Jun 2000
Posts: 24,689
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..
__________________
_____________________________________
Only 29,000 posts to catch SCHWING!!!
_____________________________________
TT-East Questions and Answers here TT-East
________________________________________
TT-East 2008 Primary Organizer
TT-East 2007 Primary Organizer
TT-East 2006 Primary Organizer
TT-East 2005 Attendee
CT GTG Coordinator
CT MOD Day Headquarters "self proclaimed"
---------------------------------------
TT-East 2008 courtesy of McPaudiTT


Linky to pics of Mods,Cars and Shows

Link to the TT-FAQ's...if it ain't here, then ask!!!

"thou shalt not flash a Porsche to get out of the way, or be damned to breathe his exhaust for eternity" - Someone wise

TRACK THOUGHT- Don't brake until you see God.... then when you do see God, count to three, then brake!

AIM name - EINTT

Current Automotive inventory...
2006 Mercedes Benz R350
2001 Audi TT 225
1977 Porsche 911s
1961 Porsche 356b
TTinCT is offline   Reply With Quote
Old 03-25-2007, 02:26 PM   #3
AudiWorld Super User
 
Join Date: Nov 2004
Posts: 10,903
Default

Nice catch, and "grassroots" repair!
__________________


Got a question about your TT? Try searching the TT-FAQ!

Got DEFCON?

My FOTKI
MCPaudiTT - DEFCON 1 is offline   Reply With Quote
Old 03-25-2007, 02:28 PM   #4
AudiWorld Senior Member
 
Join Date: Aug 2002
Posts: 1,112
Default

Great find! Bookmarked.
__________________
2002 180 QC Denim Blue (in order of install)
OEM Roof Rack, Forge DVR, REVO SPS1,
TTDA, Seat Delete
Stock 225 exhaust, 3.2 rear valance
17" RS4 replicas, Neuspeed 19 mm rear sway bar, de-vaned and de-screened maf.
cedricl is offline   Reply With Quote
Old 03-25-2007, 02:41 PM   #5
AudiWorld Super User
 
Join Date: Nov 2003
Posts: 2,008
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.

~john
__________________
I'm outta here now...
jhoeppel is offline   Reply With Quote
Old 03-25-2007, 03:52 PM   #6
AudiWorld Super User
 
Join Date: Mar 2000
Posts: 7,832
Default

Yipes, I just changed my oil..... how many miles on your TT? I don't want to crawl under again.
__________________


Farthest North modded TTQC in all the world.... Borla, Forge 6 (washer modded )DV, ABT Chip, Bilsteins, UUC springs, Neuspeed rear bar, SFC Sunroof, Bird armrest, Euro mirrors, shift light, 3M headlight protectors, TT stem caps, black front Audi rings, mud flaps, Invica-Shield on front, Yokos in winter, cedar bed, Westie, S4 (Tip) (In reserve)PS2 for training, DenBo shift boot conversion, MKI front end (re-installed), Raffi shift ****, shift ring badge, gauge pack, 3.2 type rear valance, TTDA , DG Sigma, Mintex Reds, ****, Schwing Thing Cupholder, Boost Machine, DEFCON"s on shelf. ModShack grab bar. No Mo Mods, unless they have purpose, or unless Steve tells me I need them. Flatbed club member since 2000
AkRascal is offline   Reply With Quote
Old 03-25-2007, 04:04 PM   #7
AudiWorld Super User
 
Join Date: Nov 2003
Posts: 2,008
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.
__________________
I'm outta here now...
jhoeppel is offline   Reply With Quote
Old 03-25-2007, 06:42 PM   #8
AudiWorld Super User
 
Join Date: Mar 2003
Posts: 2,203
Default

Were you getting a CEL that referred to Secondary Air Injection?
SpoiledHeeb is offline   Reply With Quote
Old 03-25-2007, 11:10 PM   #9
AudiWorld Super User
 
Join Date: Feb 2003
Location: Boston, MA
Posts: 3,416
Default been there >>

andrew.tt is offline   Reply With Quote
Old 03-26-2007, 03:49 AM   #10
AudiWorld Super User
 
Join Date: Nov 2003
Posts: 2,008
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.
__________________
I'm outta here now...
jhoeppel is offline   Reply With Quote
Old 04-28-2008, 08:53 AM   #11
Audiworld Junior Member
 
Join Date: Feb 2008
Posts: 49
Default Re: you'll only be able to access the bottom 3 with the pump in the car...

Actually, you can replace all 6 rivets without removing the pump from the car.

I removed the intercooler crosspipe to gain working room.

1) Remove the two plastic hoses and the electrical connection,
2) Remove the 3 10mm nuts from the rubber isolated mounting studs,
3) I found it easier to remove the mounting studs from the pump with a 17mm wrench so I could rotate the pump freely,
4) using a 5/32 drill bit I removed the old rivets,
5) I replaced then with 6 M4x1.5" long machine screws, using 2 washers and a nylock nut on each,

In the words of Robert Bentley... installation is reverse of removal.
kappa-q is offline   Reply With Quote
Old 08-30-2008, 10:28 AM   #12
Member
 
Join Date: Sep 2003
Posts: 1,559
Default Nice write up, changing my oil tonight and will check...

Am getting intermitant pump code.
__________________

2001 225 Quattro Coupe, Aviator, Ebony, premium, Bose
Giac-X Chip, TurboX/S H25 Bov, ****, 4 Bar Fpr, Boost Machine, Samco intake hose, Neuspeed p-flow, Neuspeed short shift, Neuspeed dogbone bushings, VF Engineering motormount, Evoheatshield, FMIC Intercooler, FK spacers 25MM R 18MM F, Mille Miglia Uno 18x8, Dunlop SP Sport Maxx 225/40/18
Eibach Springs, Bilstein Shocks, K-Mac Rear Camber kit, Neuspeed 19mm rear swaybar

2006 A4 Quattro 2.0T, 6 speed, Dolphin Gray, Gray, Premium, Revo, sport bar

1996 A4 Quattro H&R springs, Bilstein shocks, Sport bar, 4 studded snows
TTGram is offline   Reply With Quote
 
 
 
Reply

Tags
2003, a4, air, audi, b6, cost, fix, injection, primary, pump, removal, rivet, rivets, secondary, tt

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -8. The time now is 04:21 PM.


Copyright 2014 AudiWorld.com Audi Enthusiast Community