Operation CHARM: Car repair manuals for everyone.

Fuel Pump: Service and Repair






High Pressure Pump

Special tools, testers and auxiliary items required

Socket 14 mm (3150)

Torque Wrench (V.A.G 1331)

Ratchet (V.A.G 1331/1)

Socket (T40055)

Removing

CAUTION!
Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

- Drain the coolant.

- Remove front coolant pipe.

- Remove upper section of intake manifold. Refer to => [ Intake Manifold Upper Section ] Intake Manifold Upper Section.

- Remove bolts - 1 through 4 - and - 7 -.





- Loosen the union nuts - 5 - and - 6 -.

- If equipped, remove the large lifting eye - arrows -.





- Separate the electrical connector - 2 -.





Ignore - 1 -.

- Remove the bolts - arrows -.

- Carefully lift the high pressure lines.

Do not change bent shape.

- Remove high pressure pump with actuator.

Installing

Installation is in reverse order of removal, note the following:

Replace O-ring.

- To set the high pressure pump in place, lift the high pressure lines only slightly.

High pressure line connections must not show any signs of damage.

Do not change the angles of the high pressure lines.

- Place the high pressure pump with actuator into the cylinder head and fasten.

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

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

- To fasten the high-pressure line (14 mm) at high pressure pump use the (V.A.G 1331) with (V.A.G 1331/1) and (3150).





- To fasten high-pressure line (17 mm) to high pressure pump, use (V.A.G 1331) with (V.A.G 1331/1) and (T40055).





- Install intake manifold upper-section. Refer to => [ Intake Manifold Upper Section ] Intake Manifold Upper Section.

- Install front coolant pipe.

- Fill with coolant.

Tightening Specifications