Volkswagen Workshop Service and Repair Manuals

Removing and installing high-pressure pump   Caution Danger of functional impairment due to contamination/soiling To prevent the high-pressure fuel pump from running when empty (very tight tolerances) and to ensure that the engine starts quickly after parts have been renewed, it is essential to observe the following: If the high-pressure fuel pump is removed or renewed, the fuel system must be bled before the engine is started for the first time. Initial fuel filling procedure → Chapter.

Special tools and workshop equipment required

t	Counterhold tool -T10051-

t	Puller -T40064-

t	Thrust piece -T40064/1-

t	Torque wrench -V.A.G 1331-

t  Pliers -3314- »Carry out the following work sequence« Removing –  Remove toothed belt from camshaft and high-pressure pump → Chapter.

–  Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B- and pull plugs off glow pin plugs.

–  Carefully pull connector off glow plug in direction of -arrow-.

–  Separate connector -1- from fuel temperature sender -G81-. (Polo)

–  Unclip coolant return hose -arrows- and place coolant line to one side. 1)  There are different installation positions for the coolant return hose. (Golf, Golf Plus, Passat, Touran)

–  Unscrew and remove securing bolts -arrows- and place cooling water return line to one side.

–  Remove securing bolts -arrows-. Continuation for all vehicles:   Caution Make sure that no wiring connections are damaged when disconnecting the connectors. Otherwise the whole wiring harness will need to be renewed. Do not compress the pliers -3314- too firmly to separate the connectors, otherwise the support sleeve may be damaged.

–  Pull fuel supply line -arrow- off the high-pressure pump.

–  Unscrew -1, 3, 4-. Separate connector -arrow- from fuel metering valve -N290-.

–  Unscrew bolts -4- and then remove bracket.

–  Pull off fuel return line -2-.

–  Remove high-pressure fuel line between high-pressure pump and high-pressure accumulator → Item. –  Take toothed belt off high-pressure pump → Chapter.

–  Counterhold hub of high-pressure pump using counterhold -T10051- and unscrew securing nut -1-.

–  Apply puller -T40064- with thrust piece -T40064/1- and pin -T40064/2- as shown and detach hub from high-pressure pump. If necessary, counter-hold with a 24 mm open-ended spanner

–  Unscrew securing bolts -arrows- for high-pressure pump. –  Remove high-pressure pump. Installing Installation is carried out in the reverse sequence of removal. Specified torques for fuel system → Chapter Specified torques of toothed belt drive (Golf, Golf Plus, Touran, Passat) → Chapter Specified torque of toothed belt drive (Polo) → Chapter.

Specified torques -1, 3, 4- In illustration 1 = 8 Nm In illustration 3 = 8 Nm In illustration 4 = 20 Nm –  Connect vehicle diagnostic tester. –  Read event memory and erase stored event entry if necessary. –  Filling/bleeding high-pressure pump/fuel system → Chapter. –  Perform the function „Resetting engine control unit programmed values“ in „Guided functions“.