Volkswagen Workshop Service and Repair Manuals

Removing and installing high-pressure pump   Caution t  Risk of irreparable damage to high-pressure pump if allowed to run dry. t  The high pressure pump must be filled with fuel before the engine is started the 1st time → Chapter. (It is important not to allow the high-pressure pump to run while still empty.) t  Protect open fuel connections from dirt entrainment using suitable methods under all circumstances.

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- Removing –  Observe rules for cleanliness → Chapter. –  Remove toothed belt from camshaft and high-pressure pump → Chapter.

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

–  Disconnect connector -1- and remove bolts -arrows-.   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.

–  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-. –  Unscrew securing bolts of coolant line from intake manifold and lay coolant line to side. –  Pull fuel return line off high-pressure pump. –  Pull fuel return line off high-pressure accumulator (fuel rail) and lay it to side. –  Remove fuel supply line between high-pressure pump and high-pressure accumulator (fuel rail). –  Remove toothed belt pulley from high-pressure pump.

–  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 pull hub off 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 Install in reverse order. Specified torques for fuel system → Chapter Specified torques for toothed belt drive → Chapter