High Pressure Fuel Pump

High Pressure Fuel Pump

Special tools, testers and auxiliary items required

• Counter-holder tool (T10051)

• Socket (T40055)

• Puller (T40064)

• Pressure piece (T40064/1)

• Torque Wrench (V.A.G 1331)

• Ratchet (V.A.G 1331/1)

• Spring-type clip pliers (VAS 6362)

• Engine bung set (VAS 6122)

CAUTION!
• Follow the safety precautions when working on the diesel direct injection system. Refer to --> [ Safety Precautions ] Safety Precautions.

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

Always follow these instructions before and during work.

Removing

Requirements

• Ignition switched off.

• Engine must be cold.

• Only remove the high pressure fuel pump when the engine is cold.

• Make sure no contaminants enter the fuel system when removing the high pressure fuel pump.

• Seal the fuel system connections with sealing plugs from the engine bung set (VAS 6122).

Procedure

- Remove toothed belt from the camshaft and the high pressure fuel pump. Refer to --> [ Toothed Belt, Removing, Installing and Tensioning ] Toothed Belt, Removing, Installing and Tensioning.

- Disconnect connector from the fuel temperature sensor - 1 - and fuel metering valve on the high pressure fuel pump - 2 -.





- Loosen spring clips - 3 and 4 - with the spring clip pliers (VAS 6362) and disconnect the fuel lines at the high pressure fuel pump.

- Seal lines so that the fuel system is not contaminated by dirt etc.

- Loosen high pressure line or fuel lines - arrows - on the intake manifold.





- Remove protective strip --> [ 1 Protective Strip ] Removal and Replacement.

- Remove connector on fuel injectors - A -, the exhaust pressure sensor 1 - B - and the fuel pressure sensor - C -.





- Remove coolant line bolts - arrows - from the intake manifold and lay line in front of the intake manifold.

- Unclip wiring harness from wiring guide for the glow plugs.

CAUTION!
Always follow the procedure "Glow Plug Connectors, Disconnecting and Installing".

- Remove glow plug connectors. Refer to --> [ Glow Plug Connectors ] Glow Plug Connectors.

- Remove high pressure line --> [ 21 High Pressure Lines, 25 Nm ] Removal and Replacement between the high pressure fuel pump and rail element (high pressure reservoir).

- Remove toothed belt sprocket from high pressure fuel pump.

- Counterhold high pressure fuel pump hub with counterhold tool (T10051) and remove nut - 1 -.





- Position puller (T40064) with the thrust piece (T40064/1) as illustrated and remove the hub from the high pressure fuel pump. Counterhold with a 24 mm open end wrench if necessary.





- Remove high pressure fuel pump bolts - arrows -.





- Remove high pressure fuel pump.

Installing

Install in reverse order of removal, noting the following:

• Make sure no contaminants enter the fuel system when installing the high pressure fuel pump.

• Only remove sealing plugs right before installing the fuel lines.

• Do not change the angles of the high pressure lines

• Make sure lines connections are securely fastened.

• Do not swap supply and return lines.

- Tighten union nuts for the high-pressure lines by hand.

- Make sure the high-pressure lines are seated free of stress.

- Use torque wrench (V.A.G 1331) with the ratchet (V.A.G 1331/1) and socket (T40055) to tighten high pressure lines.





For tightening specifications

• --> [ Toothed Belt Drive Assembly Overview ] Toothed Belt Drive Assembly Overview

• --> [ Fuel System Assembly Overview ] Removal and Replacement

- Install and tension toothed belt. Refer to --> [ Toothed Belt, Removing, Installing and Tensioning ] Toothed Belt, Removing, Installing and Tensioning.

- Fill the fuel system. Refer to --> [ Fuel System, Filling ] Fuel System, Filling.