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Injectors > < High-pressure pump - exploded view

A3 Mk2

Removing and installing high-pressure pump
Removing and installing high-pressure pump
Removing
  Note
t  The high-pressure pump must only be removed when the engine is cold.
t  When installing the high-pressure fuel pump, it is essential to ensure that no dirt enters the fuel system.
t  Use a cloth to catch escaping fuel.
t  The O-ring must always be renewed.
t  Always ensure that the high-pressure fuel pipes are free of tension when tightening the connections.
  WARNING
Fuel system operates under high pressure. Always dissipate fuel pressure prior to opening fuel system. For procedure, refer to → Chapter
–  Remove engine cover panel → Chapter.
–  Remove cover with oil separator (engine code letters BYT only) → Chapter.
   
–  Detach electrical connector -2- from fuel pressure regulating valve -N276-.
  A24-10436
–  Disconnect both fuel lines -arrows-.
  A24-10443
–  Remove 2 bolts -arrows-.
–  Carefully pull out high-pressure fuel pump. It is possible that the roller tappet may remain lodged in the vacuum pump.
Installing
–  Renew O-ring for high-pressure pump.
–  Fit roller tappet in vacuum pump (check roller tappet for damage first).
  Note
t  The roller tappet must be positioned at the lowest point when installing the high-pressure pump.
t  If the old high-pressure pump is re-installed, or if a used pump is installed, the connecting piece on the pump for the fuel supply line must be renewed. Refer to: high-pressure pump - exploded view → Chapter.
–  Turn crankshaft until roller tappet is positioned at lowest point.
–  Fit high-pressure pump in vacuum pump.
–  Tighten bolts hand-tight.
–  Renew connecting piece at high-pressure pump.
l  Tightening torque: refer to exploded view of high-pressure pump → Chapter.
–  Now tighten bolts in diagonal sequence to specified torque, refer to high-pressure pump - exploded view → Chapter.
–  Tighten union nut on fuel supply line hand-tight. Align so that parts are free of tension.
l  Tightening torque for fuel supply line (union nut): Intake manifold - exploded view → Chapter.
  A24-10436
–  Re-attach electrical connector -2- for fuel pressure regulating valve -N276-.
–  Put back fuse if it has been removed.
  Note
Check fuel system for leaks.
  A24-10436

Injectors > < High-pressure pump - exploded view