Installing High-Pressure Pump

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.

• 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.
• Escaping fuel must be soaked up using suitable binding material.
• The fuel system must be depressurised 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.
• 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.

The tightening specifications for the basic engine are stored centrally. WM 1X00IN TIGHTENING TORQUES, TIGHTENING SEQUENCE AND ASSEMBLY OVERVIEW (PANAMERA S E-HYBRID, PANAMERA S HYBRID) / WM 2X00IN TECHNICAL VALUES (PANAMERA, PANAMERA S, PANAMERA S EXECUTIVE, PANAMERA 4, PANAMERA 4S, PANAMERA 4 S EXECUTIVE) or WM 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS (PANAMERA, PANAMERA 4, PANAMERA TURBO, PANAMERA TURBO EXECUTIVE, PANAMERA TURBO S, PANAMERA TURBO S EXECUTIVE, PANAMERA GTS) . 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 (26 ftlb.) Nm   . 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.

1. When re-installing a used high-pressure pump, check the drive coupling and Oldham coupling for signs of wear. Oldham coupling for camshaft
   Fig 1: Oldham Coupling For Camshaft

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2. 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.
3. Replace sealing ring for high-pressure pump and grease lightly with Kluber Syntheso GLEP 1.
4. When installing the high-pressure pump, connect the cable plug for the flow control valve -arrow-  .
   Fig 2: Cable Plug For Flow Control Valve

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5. Install high-pressure pump -1-  while turning it and fit union nut -6-  .
   Fig 3: High-Pressure Pump, Naturally Aspirated Engine

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   1. High-Pressure Pump
   2. High-Pressure Line
   3. M6 screw on low pressure line
   4. Low-pressure line; counter at the hexagon on the high-pressure line
   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

6. 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.
7. Using the leak test equipment, blow the fuel out of the high-pressure pump. Refer to WM 243001 CHECKING FUEL COLLECTION PIPE FOR LEAKS (PANAMERA TURBO, PANAMERA TURBO EXECUTIVE, PANAMERA TURBO S, PANAMERA TURBO S EXECUTIVE) 
8. 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 ring wrench  with Nr.98-1 Pos.2 - adapter  can be used if necessary.
   Fig 4: High-Pressure Line

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9. Perform leak test on high-pressure pump. Refer to WM 243001 CHECKING FUEL COLLECTION PIPE FOR LEAKS (PANAMERA TURBO, PANAMERA TURBO EXECUTIVE, PANAMERA TURBO S, PANAMERA TURBO S EXECUTIVE) 
10. Fit crash panel for high-pressure pump. To do this, position and fit the three screws on the crash panel.
11. Fit holder for cooling water tube -7-  . To do this, fit a hexagon-head bolt -6-  . Tightening torque 10 (7.5 ftlb.) Nm 
    Fig 5: Peripheral Engine Cooling Water Tubes

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