Installing High-Pressure Pump

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

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. 
• 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. 

1. Clean sealing surfaces.
   1. 1.1. Grease O-ring on high-pressure pump with a little Kluber Syntheso Glep (Part No. 000.043.204.68).

      Information 

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

      Information 

      • Ensure everything is clean when working on the fuel system. 
      • Even the smallest particles of dirt can cause problems and damage to the high-pressure system. 
2. Fit high-pressure pump.
   1. 2.1. Check the clutch position at the outlet sprocket. Check the deeper groove (approx. 13.5 mm) -arrow-  .
      Fig 1: Locating Deep Groove On Outlet Sprocket

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   2. 2.2. Position the high-pressure pump driver -1-  so that the high driving journal -A-  engages in the deeper groove.
      1. Driver
      1. Dimension A = 11.5 mm
      2. Dimension B = 7 mm
      Fig 2: Positioning High-Pressure Pump Driver

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   3. 2.3. Insert the high-pressure pump gently in the fitting bore on the cylinder head.
3. Fasten high-pressure pump and place fuel lines.
   1. 3.1. Coat fuel line union nuts and high-pressure pump screw sockets with lubricant OKS 1700 using a clean brush.
   2. 3.2. After positioning the high-pressure pump, fit the high-pressure line union nut first, then the low-pressure line union nut. Screw union nuts by hand as far as possible.
   3. 3.3. Fit and tighten M6 x 25 external Torx screws (E10) -1 and 2-  .

      → Tightening torque: 13 Nm (9.5 ftlb.) 

      Fig 3: Identifying High-Pressure Pump Screw Tightening Sequence

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4. Installing structure protection.
   1. 4.1. Position and tighten external Torx screws (E10) M6 x 40 -3-  and M6 x 25 -4 and 5-  .

      → Tightening torque: 13 Nm (9.5 ftlb.) 

5. Tighten union nut (a/f 14) on high-pressure line. Tool: Crow foot wrench Nr.195-1 -1-  .

   → Tightening torque: 20 Nm (15 ftlb.) 

   Fig 4: Identifying High-Pressure Line Fuel Pump

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6. Tighten union nut (a/f 17) on low-pressure line. Tool: Crow foot wrench Nr.195  .

   → Tightening torque: 20 Nm (15 ftlb.) 

   Fig 5: Identifying Low-Pressure Line High-Pressure Pump

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Plug in connector for flow control valve.