High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Ratchet, Reversible (V.A.G 1331/1)

• Open End Spanner Insert 14 mm (V.A.G 1331/9)

• Socket (T40058)

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.

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

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






- Remove the cover - arrow -.






- Remove the bolts - arrows - and the union nut - 2 - and push the fuel supply line to the side.






• Do not change the shape of the fuel supply line.

• Ignore - 1 -.

- Disconnect the connector - 1 -.






- Remove the threaded connections - 2 -.

- Remove the bolts - arrows - and pry the end cover up carefully.

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

- Remove the high pressure pump and roller tappet.

Installing

Install in reverse order, paying attention to the following:

Tightening specifications, refer to:

• => [ High Pressure Pump Overview ] High Pressure Pump Overview

• => [ High Pressure Pump - Tightening Specification and Sequence ] 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.

• If a new high pressure pump is installed, the opening near the fuel metering valve (N290) must be sealed with a sealing plug (shear bolt). Tighten the bolt till it is sealed

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






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

- Insert the (T40058) guide pins as follows:






• The large diameter - arrow 1 - faces the engine.

• The small diameter - arrow 2 - faces the adapter.

- Turn the crankshaft with the (T40058) and offset wrench in direction of engine rotation - arrow -. While doing this, press the plunger into the housing until it reaches the lowest point.






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

- Tighten the bolts on the high pressure pump. 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.

- Fuel system, checking for leaks. Refer to => [ Fuel System, Checking for Leaks ] Fuel System, Checking For Leaks.