SEAT Workshop Service and Repair Manuals

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

t  Torque wrench -V.A.G 1410-

t  Hose clip pliers -VAS 6340- Removal: Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter.

–  Lift off engine cover panel at points -1- and pull it forwards in direction of -arrow-.   WARNING The injection system is sub-divided into a high pressure system (max. approx. 120 bar) and a low pressure system (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-. –  Remove intake connecting pipe → Item.

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

–  Remove wiring guide -2- and take clip -4- off high-pressure line.   Note Use a spanner to counterhold threaded connections on high pressure pump and on lower part of intake manifold when loosening union nuts.   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. –  Loosen union nuts -1- and -3- of high-pressure line.

–  Evenly unscrew securing bolts -arrows-.

–  Pull high-pressure pump -3- and roller tappet -1- out of camshaft housing. Installation   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. Installation is carried out in the reverse sequence; note the following:   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 -arrows- by hand until bolt heads are seated on flange. –  Tighten securing bolts -arrows- evenly until flange is seated on camshaft housing. Tightening torque: 20 Nm

–  Tighten union nuts of high-pressure line -1- and -3- hand-tight. –  Install wiring guide -2- and fit clip -4- on high-pressure line. Tightening torque of the fixing bolts of the guide: 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 nut -1- of high-pressure line to 18 Nm. –  Tighten union nut -3- of high-pressure line to 18 Nm.

–  Secure fuel supply line and connector -arrows- on high-pressure pump.

–  Reconnect fuel supply line -arrow-. –  Install intake connecting pipe and air filter → Chapter.