SEAT Workshop Service and Repair Manuals

Removing and installing high-pressure pump t  Removing → Anchor t  Installing → Anchor Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required

t  Torque wrench -VAG 1410-, see equivalent → Anchor.

t  Base -VAS 6340-, see equivalent → Anchor Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter.   WARNING The injection system is in a high pressure system (max. approx. 120 bar) and a low pressure system (approx. 6 bar). The fuel pressure in the high-pressure section must be reduced to a residual pressure of 6 bar prior to opening the high-pressure system. The work procedure for this is described in the chapter where the pressure reduction in the high pressure system is described → Chapter.

–  Separate the fuel supply hose -arrow-.   Note Catch the fuel coming out with a rag.   Caution The high-pressure pump must be kept only in the enclosure during removal or installation! If the spring package of the high-pressure pump releases, the pump becomes untight and must be replaced. –  Disconnect the plug connection -1- and the fuel supply line -2- from the high-pressure pump.

–  Loosen the union nuts -3- and remove the high-pressure pipe.   Note Counterhold the bolted connections of the high-pressure pump and the fuel rail by loosening the union nuts with a screwdriver. –  Extract the attachment bolts -4- of the high-pressure pump and remove the pump using the sliders from the cylinder head cover. Installing   Caution The high-pressure pump must be kept only in the enclosure during removal or installation! If the spring package of the high-pressure pump releases, the pump becomes untight and must be replaced.   Note t  Moisten the roller tappet of the high pressure pump with clean engine oil. t  The O-ring of the high-pressure pump must be renewed. –  Fit the roller tappet -1- in the camshaft housing.

–  Place a new oiled O-ring -2- in the groove of the high pressure pump -3-. –  Fit the high-pressure pump -3- on the cylinder head cover. –  Screw in the securing screws -4- by hand until the heads of the screws rest upon the flange.

–  Tighten the securing screws equally until the flange rests on the camshaft housing. Tightening torque: 20 Nm   Note Counterhold the bolt connections of the high-pressure pump and the fuel rail by tightening the union nuts with a spark plug spanner. –  Tighten the union nuts -3- on the high-pressure line to 18 Nm. –  Fasten the fuel supply pipe -2- and the connector -1- on the high-pressure pump.

–  Connect the fuel supply hose -arrow-.