High Pressure Fuel Pump

High Pressure Fuel Pump

CAUTION!
• Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

• For safety reasons, interrupt the current supply to the fuel pump. Refer to => [ Safety Precautions ] Safety Precautions before opening the fuel system because the fuel pump is activated by the driver door contact switch.

• Do not disassemble the high pressure pump!

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Safety Precautions.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

Removing

- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.

- Set the engine to Top Dead Center (TDC).

- Disconnect the connectors - 1 and 2 -.





CAUTION!
The fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before disconnecting the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

Vehicles through 05.06





- Remove the fuel pipe - 4 - from the fitting - 3 -. Counter hold the fitting - 3 - while doing this.

- Counter hold the threaded support - 1 - and remove the banjo bolt - 2 -.

Vehicles from 06.06





- Open the hose clamp - 1 - and remove the fuel hose.

- Counter hold the fitting - 2 - and remove the fuel pipe - 3 -.

Continuation for All

- Remove the bolts - arrows - and carefully pull out the high pressure fuel pump.





• The lifter - item 1 -=> [ Lifter ] High Pressure Fuel Pump Overview can remain inserted in the cylinder head under some circumstances.

Installing

- Replace the high pressure fuel pump O-ring and lightly lubricate it with clean engine oil.

- Check the lifter plunger - item 1 -=> [ Lifter ] High Pressure Fuel Pump Overview for damage and insert it into the cylinder head.

- Place the high pressure pump carefully on the cylinder head and install the bolts - arrows - hand tight.





- Install the fuel pipes to the pump hand tight.

• Check the tightening specification for the threaded support before installing the fuel pipes.

- Tighten all bolts and fuel pipes to the required specification. Refer to => [ High Pressure Fuel Pump Overview ] High Pressure Fuel Pump Overview.

- Restore the interrupted power supply.

The rest of the installation is performed in the reverse order of removal.