High Pressure Fuel Pump

High Pressure Fuel Pump

Special tools, testers and auxiliary items required

• Camshaft Gear Counter-Holder (T10051)

• Socket (T40055)

• Puller (T40064)

• Pressure Pad for T 40064 Tool (T40064/1)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Ratchet, Reversible (V.A.G 1331/1)

• Hose Clip Pliers (VAS 6362)

• Engine Bung Set (VAS 6122)


• Follow the safety precautions when working on the diesel direct injection system. Refer to => [ Safety Precautions ] Diesel Fuel Injection.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Diesel Fuel Injection.

Always follow these instructions before and during work.

Requirements

• Ignition is turned off.

• Engine must be cold.

• Only remove the high pressure fuel pump when the engine is cold.

• Make sure no contaminants enter the fuel system when removing the high pressure fuel pump.

• Seal off the connections in the fuel system using plugs from the engine bung set.

Removing

- Remove the toothed belt from the camshaft and the high pressure fuel pump. Refer to => [ Toothed Belt ] Toothed Belt.

- Disconnect the fuel temperature sensor connector - 1 - and the fuel metering valve connector - 2 - on the high pressure fuel pump.






- Loosen the spring clamps - 3 and 4 - using hose clip pliers (VAS 6362) and disconnect the fuel lines from the high pressure fuel pump.

- Seal the lines so that the fuel system is not contaminated by dirt, etc.

- Loosen the high pressure line and fuel line bolts - arrows - on the intake manifold.






- Remove the protective strip, if equipped.

- Disconnect the fuel injector connectors - A -, the exhaust pressure sensor 1 connector - B - and the fuel pressure sensor connector - C -.






- Remove the coolant line bolts - arrows - from the intake manifold and lay the line in front of the intake manifold.

- Unclip the wiring harness from the wiring guide for the glow plugs.


Always follow the procedure "Glow Plug Connectors, Disconnecting and Connecting".

- Disconnect the glow plug connectors. Refer to => [ Glow Plug Connector, Disconnecting and Connecting ] Glow Plug Connector, Disconnecting and Connecting.

- Remove the high pressure line between the high pressure fuel pump and fuel rail.

- Remove the toothed belt sprocket from the high pressure fuel pump.

- Counter-hold the high pressure fuel pump hub using the camshaft gear counter-holder (T10051) and remove the nut - 1 -.






- Position the puller (T40064) with the pressure pad for T 40064 tool (T40064/1) and the pin (T40064/2) as illustrated and remove the hub from the high pressure fuel pump. Counter-hold with a 24 mm open end wrench, if necessary.






- Remove the high pressure fuel pump bolts - arrows -.






- Remove the high pressure fuel pump.

Installing

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

• Make sure no contaminants enter the fuel system when installing the high pressure fuel pump.

• Only remove the sealing plugs right before installing the fuel lines.

• Do not change the angles of the high pressure lines

• Make sure lines connections are securely fastened.

• Do not swap supply and return lines.

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

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

- Use the torque wrench (5-50 Nm) (V.A.G 1331) with the ratchet, reversible (V.A.G 1331/1) and the socket (T40055) to tighten the high pressure lines.






Tightening Specifications

• => [ Toothed Belt Overview ] Toothed Belt Overview

• => [ Fuel Rail and Injectors Overview ] Service and Repair

- Install and tension the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.

- Fill the fuel system. Refer to => [ Fuel System, Filling and Bleeding ] Fuel System, Filling and Bleeding.