Installing High-Pressure Pump
- Danger of poisoning or suffocation
- Danger of burns to the eyes and skin
- 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.
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapors.
- Attach warning sign in a clearly visible position.
- Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
- Secure collection containers/vessels to prevent them from tipping over.
NOTIFICATION
Dirt on injection system components
- Material damage
- Rough-running engine
- Bad exhaust emissions
- 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.
- Emerging fuel
- Risk of fire
- 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
- Escaping fuel must be soaked up using suitable binding material.
- The fuel system must be depressurized before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals that were removed must always be replaced.
- Never use 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.
Information
- Following replacement of the high-pressure pump and engine, the values for the high-pressure adaptation must be reset using the PIWIS Tester. Then carry out a test and adaptation drive.
Information
The tightening specifications for the basic engine are stored centrally.
> Refer to 1X00IN Technical values in the appropriate service information
/
or
> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS
Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
If the fitting in the high-pressure pump is loosened accidentally, tighten it to > Tightening torque 35 Nm (26 ftlb.) . When re-installing the low-pressure line on the high-pressure pump, the distance from the high-pressure line must be set to at least 5 to 8 mm.
- When re-installing a used high-pressure pump, check the drive coupling and Oldham coupling for signs of wear. >
Oldham coupling for camshaft
- Check the position of the Oldham coupling on the intake camshaft using a mirror. Turn the drive coupling of the high-pressure pump into the correct installation position by hand.
Information
- 000043 204 68 (Status 02/07) "Kluber Syntheso GLEP 1" is a neutral-reaction assembly grease for connection pieces and sealing rings in oily or water-carrying areas.
- Use "Kluber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks.
- "Kluberplus S06-100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06/08). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.
- Replace sealing ring for high-pressure pump and grease lightly with Kluber Syntheso GLEP 1.
- When installing the high-pressure pump, connect the cable plug for the flow control valve -arrow-
.
Cable plug for flow control valve
- Install high-pressure pump -1-
while turning it and fit union nut -6-
.
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
High-pressure pump, turbo engine
1 High-pressure pump 2 High-pressure line; (3 turns, tighten, loosen, tighten) 3 M6 screw on low-pressure line 4 Low-pressure line; (3 turns, tighten, loosen, tighten); counter at hexagon on high-pressure pump 5 Screw socket, M8 6 Screw socket, M6 7 Protective plate 8 Screw, M6 x 20 inset Required line distance (5 to 8 mm) between components - Screw on low-pressure line -4- . The tool > Nr.98-1 Pos.1 - open-ended socket ring wrench with > Nr.98-1 Pos.2 - adapter can be used if necessary.
- Using the leak test equipment, blow the fuel out of the high-pressure pump.
- Fit high-pressure line to the adapter for the high-pressure pump. Allow a gap of 5 to 8 mm to the low-pressure line.
Tighten high-pressure line in three stages. > Nr.185 - Open-ended socket ring wrench must be used together with a torque wrench. The tool > Nr.98-1 Pos.1 - open-ended socket rin g wrench with > Nr.98-1 Pos. 2 -adapter can be used if necessary.
High-pressure line
- Perform leak test on high-pressure pump.
- Fit crash panel for high-pressure pump. To do this, position and fit the three screws on the crash panel.
- Fit holder for cooling water tube -7-
. To do this, fit a hexagon-head bolt -6-
. > Tightening torque 10 Nm (7.5 ftlb.)
Peripheral engine cooling water tubes