Volkswagen Workshop Service and Repair Manuals

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

t  Torque wrench (4 … 20 Nm) -V.A.G 1410-

t  Hose clip pliers -VAS 6340- Removing Observe safety precautions → Chapter.   WARNING The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar). Prior to opening the high-pressure area, 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-.   Note Catch escaping fuel in a cloth.   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. –  Pull connector -1- and fuel supply line -2- off high-pressure pump.

–  Loosen union nuts -3- and remove high-pressure line.   Note Use a spanner to counterhold threaded connections on high-pressure pump and on fuel rail when loosening union nuts. –  Remove securing bolts -4- from high-pressure pump and pull it out of cylinder head cover using tappet. Installing   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.   Note t  Moisten high-pressure pump roller tappet with clean engine oil. t  The high-pressure pump O-ring must be renewed. –  Slide roller tappet -1- into cylinder head cover.

–  Insert new, lubricated O-ring -2- in groove of high-pressure pump -3-. –  Place high-pressure pump -3- onto cylinder head cover. –  Screw in securing bolts -4- by hand until bolt heads are seated on flange.

–  Tighten securing bolts evenly until flange is seated on camshaft housing. Specified torque: 20 Nm   Note Counterhold threaded connections on high-pressure pump and on fuel rail using wrench when tightening union nuts. –  Tighten union nuts -3- of high-pressure line to 25 Nm. –  Secure fuel supply line -2- and connector -1- to high-pressure pump.

–  Reconnect fuel supply line -arrow-.