High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Flare Nut Attachment 17 mm (T10456)

Removing

• Follow the safety measures for releasing the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

• Fuel pipes are under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Before loosening the fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening.

- Remove the cover - 1 - from the air duct, disengage the clips sideways to do so.






- Unclip the air duct - 2 -.

- Remove the air filter housing and connecting pipe, while doing this remove the bolt - A -, disconnect the connector - B - and remove the spring clip - C -. When reinstalling, observe the mark - D -.






- Remove the air duct bolts - arrows - from the lock carrier and remove the air duct.






- Remove the lifting eye bolts - arrows - and lifting eye - A -.






- Disconnect the connector - arrow - from the fuel pressure sensor.






- Disconnect the low pressure hose - 1 -.

- Remove the high pressure line - 2 -. When doing this, counter hold the connections on the high pressure pump using a wrench.

• For the union nuts, use the flare nut attachment 17 mm (T10456).

• The low pressure hose must always be replaced because it is damaged when it is removed from the ridged connections. Fuel rail, injectors and high pressure pump overview. Refer to => [ Fuel Rail, Injectors and High Pressure Pump Overview ] Fuel Rail, Injectors and High Pressure Pump Overview.

- Disconnect the connector - A -, remove the bolts - arrows - and remove the high pressure pump - B - from the engine.






Installing






- Check the high pressure pump cam follower for damage; replace it if necessary.

- Insert the lubricated cam follower - 1 - with the guide - 2 - perpendicularly into the cylinder head.

- Rotate the engine at the vibration damper slowly in engine rotation direction. When doing this, press the cam follower in the - direction of the arrow - until it reaches the deepest point in the cylinder head.

- Replace the O-ring on the high pressure pump and coat it lightly with clean engine oil.

- Install the high pressure pump and evenly tighten the bolts - arrows -.






For the correct tightening specification, refer to => [ Fuel Rail, Injectors and High Pressure Pump Overview ] Fuel Rail, Injectors and High Pressure Pump Overview.

- Tighten the connections on the high pressure pump for the low pressure hose at the high pressure pipe.

Connection for the high pressure pipe: 40 Nm

Connection for the low pressure hose: 28 Nm

• The low pressure hose must always be replaced because it is damaged when it is removed from the ridged connections.

• The low pressure hose and high pressure pipe must not touch after being tightened. Ensure sufficient clearance.

- Install the new low pressure hose - A -. Pay attention to the installation marks and position of the spring clamps - arrows -.






- Install the high pressure pipe and tighten by hand.

- Tighten the high pressure pipe - A - evenly while counter holding the high pressure pipe in the - direction of the arrow -. The high pressure pipe - A - and low pressure hose - B - must not touch after being tightened.






For the union nuts, use the flare nut attachment 17 mm (T10456).

• Tightening specification: 28 Nm

Install the engine lifting eye.