Installing High-Pressure Pump

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Wear personal protective gear.

→ Do not smoke, eat or drink in the work area.

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

→ Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.

→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.

→ Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.

→ Only install clean parts. Do not take spare parts out of the packaging until just before installation.

→ Never use compressed air when the system is open. Do not move the vehicle.

→ Perform leak test.

Information 

• Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting. 

Information 

• Absorb any escaping fuel using a suitable binding material or a cloth. 
• Cloths which have absorbed fuel must be disposed of according to the applicable national laws. 
• The fuel system must be depressurised before starting work on it. 
• Only work on the fuel system in well-ventilated rooms. 
• Any seals which have been removed must always be replaced. 
• Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors. 

1. Check that the drive tappet -1-  is installed correctly. The drive tappet has a twist lock on the side. -2- 
   Fig 1: Checking Drive Tappet

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2. Check sealing ring of high-pressure pump for signs of damage and replace if necessary. Avoid shearing off the sealing ring during installation.
3. Place high-pressure pump in installation position, then insert bottom left screw.
   Fig 2: Installing High-Pressure Pump

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4. Connect the lower cable plug for the flow control valve. -arrow- 
   Fig 3: Connecting Lower Cable Plug For Flow Control Valve

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5. Insert the three screws for the high-pressure pump. For the bottom screw use a thin tool and very carefully press the coolant pipe down -2-  . Press the high-pressure pump against the resistance of the spring and screw in screws (twist crankshaft if necessary until the drive tappet is at its lowest point). Fit screws -1-  . → Tightening torque: 10 Nm (7.5 ftlb.) 
   Fig 4: Locating High-Pressure Pump Mount

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   Fig 5: Identifying Accessibility Of Threaded Joint

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6. Position high-pressure line (fuel line) at the union nuts -5 and 6-  and tighten. To do this, counter at the hexagon. → Tightening torque: 22 Nm (16 ftlb.) 
7. Position low-pressure line (fuel line) at the union nuts -4 and 7-  and tighten. To do this, counter at the hexagon. → Tightening torque: 27 Nm (20 ftlb.) 
8. Connect cable plug for high-pressure sensor -3-  .
   Fig 6: Identifying High-Pressure System Threaded Connection

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9. Inspect high-pressure system for leaks. → 243001 CHECKING FUEL DISTRIBUTION PIPE (FUEL RAIL) ON DFI ENGINES FOR LEAKS