High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Torque wrench 5-50 Nm (VAG 1331)

• Hose clip pliers (VAS 6362)

Conditions

• Engine cold.

• High pressure pump with fuel pressure regulator valve assembly overview. Refer to --> [ High Pressure Pump with Fuel Pressure Regulator Valve Assembly Overview ] High Pressure Pump With Fuel Pressure Regulator Valve Assembly Overview.

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

• Catch leaking fuel with a cloth.

Removing

- Read the safety precautions before beginning work. Refer to --> [ Safety Precautions ] Safety Precautions.

- Observe the rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

CAUTION!
Fuel system is under pressure! Before opening high pressure components of the fuel injection system, the fuel pressure must be relieved to residual pressure, procedures. Refer to --> [ High Side Fuel Pressure Releasing ] High Side Fuel Pressure Releasing.

- Remove the engine cover. Refer to --> [ Engine Cover ] Engine Cover.

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





- Open both fuel lines - arrows -.





- Remove the 2 bolts - arrows -.





- Carefully remove the high pressure pump. The roller tappet may stay in the cylinder head.

Installing

Tightening specification:

• Intake manifold assembly overview. Refer to --> [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.

• High pressure pump with fuel pressure regulator valve assembly overview. Refer to --> [ High Pressure Pump with Fuel Pressure Regulator Valve Assembly Overview ] High Pressure Pump With Fuel Pressure Regulator Valve Assembly 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.

- Carefully place the high pressure pump with the roller tappet (pay attention to the groove) in the opening in the cylinder head. Check the roller tappet for damage first.

- Tighten the bolts - arrows - by hand.





- Before installing the fuel lines, check the torque of the connections 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.

- Connect 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 ] Fuel System, Checking for Leaks.