Over time, the aluminum that was pressed down around the nipple base gets loose from engine vibration etc. I know the old ones were two piece as far as the vac pump nipple goes. I'm not sure if the new vac pump nipples are of the same cast as the rest of the vac pump body or not now. You will also need a new vacuum pump to head seal when you remove the vac pump FYI. This may or may not fix you issue, but is certainly worth doing especially since these TDI's are aging.
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Once the RTV cures you will now have a mechanically stabilized and leak free nipple connection. Once that's done, clean the nipple area again really well, and apply some UltraGrey RTV to the nipple base.
This should stabilize the nipple mechanically. Once the area is clean, use a ball peen hammer to gently tap around the cast aluminum that holds the nipple in place. Remove the vacuum pump, and clean the nipple area really well with brakeclean or similar spray cleaner. If you have movement, you know there could be potential for air in leakage.Īs a preventative maintenance item and as part of your trouble shooting effort, I would go ahead and remove the black rubber line from your vacuum pump nipple. You can check if the nipple is loose by gently pulling up and down on the rubber hose/nipple going into the pump. When the engine isn't running there isn't any vibration to vibrate the nipple and cause air in leakage. It could be that the nipple on your vacuum pump is loose allowing air to enter when the engine is running.
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