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PSA: check that secondary air injection pump!

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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.

<img src="http://www.neiu.edu/~jrhoeppe/Pump-problem.jpg">

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

<img src="http://www.neiu.edu/~jrhoeppe/Pump-closeup.jpg">

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.

<img src="http://www.neiu.edu/~jrhoeppe/Rivet-screw.jpg">

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.

<img src="http://www.neiu.edu/~jrhoeppe/Pump-fixed.jpg">

Stupid cost-cutting measure... the screw &amp; 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
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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
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Nice catch, and "grassroots" repair!
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Old 03-25-2007, 02:28 PM
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Great find! Bookmarked.
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Old 03-25-2007, 02:41 PM
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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.

~john
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Old 03-25-2007, 03:52 PM
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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
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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
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Were you getting a CEL that referred to Secondary Air Injection?
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Old 03-25-2007, 11:10 PM
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Default been there >>

<img src="http://www.squarewave.com/army/andrew/ttstuff/air_pump-001.jpg"><ul><li><a href="https://forums.audiworld.com/tt/msgs/1574799.phtml">https://forums.audiworld.com/tt/msgs/1574799.phtml</a</li></ul>
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Old 03-26-2007, 03:49 AM
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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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