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 the high pressure pump, 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

- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.

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


The fuel system is under pressure!

• Before opening high pressure components of the fuel injection system, 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 ] Engine Cover.

- Disconnect the electrical connector - 2 - from the fuel pressure regulator valve (N276).






- 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 connecting pieces (high pressure side) => [ (Item 11) Connecting Piece ] High Pressure Pump Overview.

Tightening specifications:

• Intake manifold overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

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

Install in reverse order of removal. When doing this note the following:

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

• The O-ring must always be replaced.

• High pressure fuel lines must always be fastened free of tension.

- Replace the high pressure pump O-ring.

- Insert the cam follower in the vacuum pump after checking the follower 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 connecting pieces on the high pressure pump.

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

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

- Reconnect the electrical connector - 2 - to the fuel pressure regulator valve.

- If the fuse was pulled, insert it again.

- Check the fuel system for leaks. Refer to => [ Fuel System, Checking for Leaks ] Testing and Inspection.