Volkswagen Workshop Service and Repair Manuals

Removing and installing high-pressure pump Special tools and workshop equipment required

t  Torque wrench (4…20 Nm) -V.A.G 1410-

t  Hose clip pliers -VAS 6340- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter.   WARNING The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar). Prior to opening the high-pressure area, e.g. when removing the high-pressure pump, fuel rail, injectors, a fuel line, or the fuel pressure sender -G247-, the fuel pressure in the high-pressure area must be reduced to a residual pressure of approx. 6 bar. The appropriate procedure is described in the chapter on releasing pressure in the high-pressure section → Chapter. –  Separate fuel supply line -arrow-.

–  Separate push-on couplings → Chapter.

–  Pull connector -1- and fuel supply line -2- off high-pressure pump.   Note Catch escaping fuel in a cloth.

–  Remove cable guide -2-.   Note Use a spanner to counterhold threaded connections on high pressure pump and on lower part of intake manifold when loosening union nuts. –  Loosen union nuts -1- and -3- of high-pressure line.

–  Unscrew securing bolts -1- evenly.   Caution Only grasp high-pressure pump on housing when removing and installing! When the high-pressure piston spring package loosens the high-pressure pump will leak and must be replaced.

–  Pull high-pressure pump -3- and roller tappet -1- out of camshaft housing. Installing   Caution Only grasp high-pressure pump on housing when removing and installing! When the high-pressure piston spring package loosens the high-pressure pump will leak and must be replaced.   Note t  Moisten high-pressure pump roller tappet with clean engine oil. t  The high-pressure pump O-ring must always be renewed. –  Slide roller tappet -1- into camshaft housing.

–  Insert new, lubricated O-ring -2- in groove of high-pressure pump -3-. –  Place high-pressure pump -3- onto camshaft housing.

–  Screw in securing bolts -1- by hand until bolt heads are seated on flange. –  Tighten securing bolts -1- evenly until flange is seated on camshaft housing. Specified torque: 20 Nm

–  Tighten union nuts of high-pressure line -1- and -3- hand-tight. –  Install cable guide and tighten securing bolt -2- to 8 Nm.   Note Use a spanner to counterhold threaded connections on high-pressure pump and on lower part of intake manifold when tightening union nuts.

–  Tighten union nuts -1- and -3- of high-pressure line to 18 Nm.

–  Secure fuel supply line -2- and connector -1- to high-pressure pump.

–  Reconnect fuel supply line -arrow-.