High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Ratchet (V.A.G 1331/1)

• Socket 14 mm (3150)

Removing


There is a risk of injury because the fuel is under very high pressure.

• The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

• The removal and installation of the high-pressure fuel pump can only be performed on a cold engine.

• When installing the high-pressure fuel 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.

- Remove lower section of the air filter housing. Refer to => [ Air Filter Housing, Lower Section ] Air Filter Housing, Lower Section.

- Remove bolts - arrows - and protective plate - 1 -.





- Disconnect electrical connectors - 1 - and - 6 -.





- Disconnect fuel supply line - 2 - and remove the threaded connection - 5 -.

- Remove bolts - 3 - and - 4 - on the retaining clamps.

- Remove bolts - arrows - and pry the end cover up carefully.

• Do not change the angles of the fuel lines.

• Never bend any of the fuel line mounting clamps.

• If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

- Carefully remove high pressure pump.

- Remove roller tappet - 1 - from the housing.





Installing

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

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

• Do not change the angles of the fuel lines.

• Never bend any of the fuel line mounting clamps.

• If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

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

- Check plunger - 1 - for damage and replace it if necessary.





- Coat plunger with oil and insert it with the tab - arrow A - in the guide - arrow B -.

• To insert the high pressure pump, the roller tappet must be at its lowest point.

- Rotate crankshaft in the direction of engine rotation at the vibration damper bolt while pressing the roller tappet into the cylinder head until it reaches the deepest point.

- Only lift the high pressure line slightly to insert the high pressure pump.

- Install the high pressure pump into the housing.

- Tighten bolts - arrows - by hand up to the flange.





- Tighten bolts diagonally to the tightening specification (approximately 1 turn until the bolts contact the high pressure pump).

• Tightening on just one side (bending) can damage the pump.

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

- Tighten fuel supply line union nut - 5 - by hand. Align so it is free of stress.

- Connect fuel supply hose - 2 -.

- Tighten bolts - 3 - and - 4 - on the retaining clamps.





- Connect connectors - 1 - and - 6 -.

- Tighten high pressure line to the tightening specifications => [ High pressure line, installing ] High Pressure Pump Overview





- Install protective plate - 1 -.





- Install lower section of the air filter housing. Refer to => [ Air Filter Housing, Lower Section ] Air Filter Housing, Lower Section.

• Check fuel system for leaks.