High Pressure Pump

High Pressure Pump


• 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 drivers door contact switch.

• Do not disassemble the high pressure pump!

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

• Pay attention to the rules of 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 -.







Fuel system is under pressure!

• Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

Vehicles through 05.06:






- Remove the fuel pipe union nut - 4 - at the threaded connection - 3 -. Counter hold the threaded connection - 3 - while doing this.

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

Vehicles from 05.06:






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

- Counter hold the threaded connection - 2 - and remove the fuel pipe union nut - 3 -.

Continuation for all Vehicles:

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






• The cam follower => [ (Item 1) Cam Follower ] High Pressure Pump Overview can remain installed in the cylinder head under some circumstances.

Installing

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

- Check the cam follower => [ (Item 1) Cam Follower ] High Pressure Pump Overview for damage and install 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 on hand tight.

• Check the tightening torque for the threaded connections before installing the fuel pipes.

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

- Restore the interrupted power supply.

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