Installing High-Pressure Pump

→ Perform leak test.

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

1. Tools for fitting fuel lines: 
   1. 1.1. Tool set 1: 

      Torque wrench with 3/8-inch head 

      Short 3/8-inch extension 

      Crow foot wrench Nr.195  , a/f 17

      Crow Foot Wrench Nr.195-1  , a/f 14

      Fig 1: Identifying Fuel Pump And High-Pressure Line

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 1.2. Tool set 2: Position of adapter with joint with respect to torque wrench: 90° 
      1. Torque wrench with 3/8-inch head 
      2. Insert Adapter With Joint Nr.98-1 Pos.3 
      3. Open-Jawed Wrench Insert Nr.95 Pos.1  or Open-Jawed Wrench Insert Nr.95 Pos.2 
         Fig 2: Tightening Union Nuts On Fuel Lines Using Tool

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Tightening sequence for high-pressure pump: 

      Fig 3: High-Pressure Pump Nuts Tightening Sequence

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Before installing the high-pressure pump, check the position of the driver and move it into installation position by hand if necessary. 

   Information 

   Always replace gaskets and O-rings.

   • Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68). 
2. Fit high-pressure pump.
   1. 2.1. Replace sealing ring on high-pressure pump and grease with the prescribed lubricant.
   2. 2.2. Position high-pressure pump. Position driver for mounting on the outlet camshaft.

      There is no defined driver position required as on naturally aspirated engines! 

   3. 2.3. Fit external Torx screws (E10, M6 x 25) -1 and 2-  and tighten to the prescribed torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

   Information 

   • Always perform a leak test in the high-pressure area after opening the fuel system. 
   • This is particularly important if components are disassembled and replaced. 
   • The threaded connections of the fuel lines must be coated with OKS 1710 lubricant (Part No. 000.043.303.27) before being screwed back on again. 
   • Always allow a drying time of 60 minutes for the lubricant! 
   • Blow residual fuel out of the lines and high-pressure pump (into a fuel-resistant container or cloth) using compressed air before installation. 
   • The tightening specifications must be strictly observed. 
3. Fit fuel lines on the high-pressure pump using a suitable tool.
   1. 3.1. Coat union nuts on fuel lines, cone and high-pressure pump screw sockets with lubricant OKS 1700.
   2. 3.2. Screw on union nut for fuel high-pressure line (a/f 14) -2-  by hand and then tighten it. → Tightening torque: 20 Nm (15 ft. lb.) 
      Fig 4: Identifying High-Pressure Pump And Fuel Lines

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   3. 3.3. Screw on union nut for fuel low-pressure line (a/f 17) -1-  by hand and tighten it. → Tightening torque: 20 Nm (15 ft. lb.) 
4. Perform leak test.

   → 200101 CHECKING FUEL SYSTEM (HIGH-PRESSURE SIDE) FOR LEAKS - TURBO ENGINE .

5. Fit cover for high-pressure pump.
   1. 5.1. Guide in cover for high-pressure pump.
   2. 5.2. Screw in external Torx screws (E10) M6 x 40 -3-  and (E10) M6 x 25 -4 and 5-  and tighten to the prescribed tightening torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

6. Fit heat protection panel for high-pressure pump.
   1. 6.1. Position heat protection panel -4-  , screw in three external Torx screws (E10, M6 x 12) -3-  and tighten to the prescribed torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

   2. 6.2. Insert cable plug for flow control valve -2-  and clip in cable -1-  .
      Fig 5: Identifying High-Pressure Pump And Heat Protection Panel (Naturally Aspirated Engine)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93). 
7. Fit coolant pipe.
   1. 7.1. Replace sealing ring on coolant pipe and grease with the prescribed lubricant.
   2. 7.2. Position coolant pipe -2-  , screw in external Torx screws (E10, M6 x 12) -1-  and tighten to the prescribed tightening torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

      Fig 6: Securing Coolant Pipe

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Fit supply hose for coolant pump.
   1. 8.1. Push on coolant hose -1-  and fit the spring band clamp -2-  .
      Fig 7: Identifying Coolant Pump And Coolant Hose

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.