Volkswagen Workshop Service and Repair Manuals

Removing and installing high-pressure pump

Special tools and workshop equipment required

t	Counterhold tool -T10051-

t	Puller -T40064- with T40064/1

t	Torque wrench -V.A.G 1331-

Removing   Caution t  Observe rules for cleanliness and the instructions for working on the fuel system → Chapter. t  Always follow these rules for cleanliness and instructions before starting work and while working on the fuel system. Risk of irreparable damage to high-pressure pump if allowed to run dry. The high-pressure pump must first be filled with fuel before the engine is started. The high-pressure pump must not be allowed to run while still empty. Initial fuel filling → Chapter. –  Remove toothed belt from camshaft and high-pressure pump → Chapter.

–  Unscrew bolts -2-, remove toothed belt sprocket from high-pressure pump.

–  Unscrew nut -1- on hub of high-pressure pump; counterhold with counter-hold tool -T10051- for this.

–  Position puller -T40064- with thrust piece -T40064/1- and pin -T40064/2- as shown and pull hub off high-pressure pump. Use an 24 mm open-end spanner to counterhold.

–  Unscrew bolts -2-, lay coolant return line aside.

–  Unscrew bolts -arrows-, lay coolant return line aside.

–  Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure line.

–  Disconnect electrical connectors -1- and -3-. Vehicles with high-pressure pump support

–  Remove nut -1- and bolt -2- from support -A- and remove support. Continuation for all vehicles –  Remove fuel supply hose -2- and return hose -4-.

–  Unscrew bolts -arrows- for high-pressure pump. –  Carefully remove high-pressure pump. Installing Installation is carried out in the reverse order; note the following: –  Carefully apply high-pressure pump and tighten bolts -arrows-. l  Specified torques → Chapter „Assembly overview - high-pressure pump“. Vehicles with high-pressure pump support –  If necessary, fit twin bolts for support in the high-pressure pump. Specified torque: 15 Nm.

–  Apply support, tighten nuts -1- and bolt -2- on support by hand. The support must allow itself to be moved. –  Tighten bolt -2- and then nuts -1- Specified torque: 23 Nm. Continuation for all vehicles –  Install toothed belt → Chapter. –  Install high-pressure lines → Chapter.   Caution Risk of irreparable damage to high-pressure pump if allowed to run dry. The high-pressure pump must first be filled with fuel before the engine is started. The high-pressure pump must not be allowed to run while still empty. Initial fuel filling → Chapter.