High Pressure Pump

High Pressure Pump

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Ratchet, Reversible (V.A.G 1331/1)

• 14 mm Open End Spanner Insert (V.A.G 1331/9)

Removing


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

• Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure.

- Reduce fuel pressure in high pressure area. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

- Remove bolts - arrows -.






- Remove the air ducts - 1 - and - 2 -.

- Remove the nuts - arrows - and the protective plate - 1 -.






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






- Remove the threaded connections - 2 - and - 5 -.

- Remove the bolt - 3 - on the retaining clamp.

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

• Do not change bent shape.

• Ignore - 4 -.

- Remove the high pressure pump and roller tappet.

Installing

• Tightening specifications, refer to => [ Air Filter Overview ] Service and Repair, => [ High Pressure Pump Overview ] High Pressure Pump Overview.

Installation is performed in reverse order of removal, noting the following:

• Replace O-ring.

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

• Do not bend the high pressure line to a different angle.

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






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

- Rotate the 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.

- Tighten the bolts on the high pressure pump hand-tight.

- Tighten the bolts crosswise with the required torque.

• Tightening specifications, refer to => [ High Pressure Pump Overview ] High Pressure Pump Overview

- Install the high pressure line - 2 - and - 5 -. Refer to => [ High Pressure Line ] Service and Repair.

- Connect the connectors - 1 - and - 6 -.






- Remove the bolt - 3 - on the clamp.

• Check fuel system for leaks.