High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Hose Clip Pliers (VAS 6362)

Conditions

• The engine is cold.

• High pressure pump overview. Refer to => [ High Pressure Pump Overview ] High Pressure Pump Overview.

• 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 leaking fuel with a cloth.

• Always replace the O-ring and the connection.

• Always install the high pressure fuel lines so that they are free of tension.

Removing

- Observe the safety precautions before performing any repair work.

- Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

The fuel system is under pressure!

• Before opening the high fuel pressure side components, the fuel pressure must be relieved to residual pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

- Remove the engine cover. Refer to => [ Engine Cover ] Service and Repair.

- Disconnect the fuel pressure regulator valve connector - 2 -.






- Open both fuel lines - arrows -.






- Remove the 2 bolts - arrows -.






- Carefully remove the high pressure pump. The cam follower may stay in the cylinder head.

Installing

• To insert the high pressure pump, the cam follower must be at its lowest point.

• If the same or a used high pressure pump is installed, replace the fuel supply line connections (high pressure side). Refer to - item 11 - in the => [ High Pressure Pump Overview ] High Pressure Pump Overview.

Tightening specifications, refer to the following:

• => [ Intake Manifold Overview ] Intake Manifold Overview.

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

Install in the reverse order of removal. Note the following:

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

• The O-ring must always be replaced.

• Always install the high pressure fuel line so that it is free of tension.

- Replace the high pressure pump O-ring.

- Insert the cam follower in the vacuum pump after checking the tappet for damage.

- Rotate the crankshaft until the cam follower is at the lowest point.

- Install the high pressure pump into the vacuum pump.

- Tighten the bolts - arrows - by hand.






- Replace the connections on the high pressure pump.

- Tighten the bolts - arrows - crosswise to the required torque.

- Tighten the fuel supply line union nut by hand align it so it is free of stress and tighten it.

- Connect the fuel pressure regulator valve connector - 2 -.

- If the fuse was pulled, reinsert it again.

- Check the fuel system for leaks.