High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Ratchet, Reversible (V.A.G 1331/1)

• Socket Insert AF 14 (V.A.G 1331/8)

Removing

There is a risk of injury because the fuel is under very high pressure.

• Reduce the fuel pressure down to residual pressure before opening the high pressure area of the fuel injection system.

• The high pressure pump can only be removed and installed when the engine is cold.

• When installing, make sure that no dirt enters the fuel system.

• Catch escaping fuel with a cloth.

- Reduce fuel pressure in high pressure area. Refer to => [ Releasing Pressure in High Pressure Area ] Releasing Pressure In High Pressure Area.

- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Remove the nuts - arrows - and the protective plate - 1 -.






- Disconnect the connectors - 1 and 6 -.






- Remove the bolt - 3 - on the retaining clamp.

- Remove the threaded connections - 2 and 5 -.

- Remove the bolts - arrows -.

- Carefully remove the high pressure pump. The roller tappet can remain installed.

• Do not bend the high pressure line to a different angle.

• Ignore - 4 -.

Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to => [ High Pressure Pump Overview ] High Pressure Pump Overview.

• Replace the O-ring.

• High pressure line connections must not show any signs of damage.

• Do not bend the high pressure line to a different angle.

- Check the plunger - 1 - for damage and replace it if necessary.






- Coat the plunger with oil and insert it with the tab - arrow A - in the guide - arrow B -.

- Rotate the crankshaft in the direction of engine rotation at the vibration damper bolt while pressing the roller tappet into the cylinder head until it reaches the deepest point.

- Only lift the high pressure line slightly to insert the high pressure pump.

- Push the high pressure pump down as far as possible with one hand.

- Tighten the bolts with the other hand.

- Tighten the bolts to 5 Nm alternating from side to side (be careful not to tilt the high pressure pump while tightening the bolts).

- Then tighten the bolts to the tightening specification alternating from side to side.

• Tightening specifications for bolts, refer to => [ High Pressure Pump - Tightening Specification and Sequence ] High Pressure Pump Overview

- Install the high pressure line. Refer to => [ High Pressure Line ] Service and Repair.

- Install the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Check the fuel system for leaks. Refer to => [ Fuel System, Performing Leak Test ] Fuel System, Performing Leak Test.