High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• 17 mm Socket (V.A.G 1331/6)

• SW 14 Socket, Open Ring (V.A.G 1331/8)

Removing

• The following description represents removal and installation of left high pressure pump.

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.

• Observe safety precautions when disconnecting the battery.

• The high pressure pump can only be removed when the engine is cold.

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

• Catch escaping fuel with a rag.

• The O-ring must always be replaced.

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

- With ignition switched off, disconnect Battery Ground (GND) cable.

- Remove rear engine cover.

- Disconnect electrical connectors on Low Fuel Pressure Sensor (G410) - 1 - and on Fuel Metering Valve 2 (N402) - 2 -.





• The Low Fuel Pressure Sensor (G410) located in the high pressure pump only through MY 2009.

- Remove both fuel line union nuts.

- Remove bolts - 3 -.

• Do not change the angles of the high pressure lines.

- Carefully remove high pressure pump.

- Remove roller tappet from cylinder head.

Installing

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

- Replace the O-ring for the high-pressure pump.

- Insert the roller tappet in the cylinder head after checking the tappet for damage.

• The roller tappet must be at its lowest point to insert the high pressure pump.

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

- Carefully place the high-pressure pump with the sleeve into the opening in the cylinder head.

- Tighten bolts by hand.

- Tighten bolts to the specification in an alternating sequence.

• Tightening specifications. Refer to => [ High Pressure Pump Assembly Overview ] High Pressure Pump Assembly Overview

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

• Do not change the angles of the high pressure lines.

- Hand-tighten the union nuts for the high-pressure lines.

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

- To tighten 14 mm diameter union nut on high pressure lines, use Torque Wrench (V.A.G 1331) with Socket Insert AF 14, open ring (V.A.G 1331/8).





- To tighten union nut (17 mm diameter) on high pressure lines, use Torque Wrench (V.A.G 1331) with Socket Insert, AF 17 (V.A.G 1331/6).





- Observe safety precautions after connecting battery.

- Reconnect electrical connectors on Low Fuel Pressure Sensor (G410) - 1 - and Fuel Metering Valve 2 (N402) - 2 -.





• Check fuel system for leaks.