Removing High-Pressure Pump

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.

Information 

• High-pressure pumps replaced under warranty must be sent in with protection caps (on the pump connections). Use protection caps from the new pump. Intrusion of dirt must be avoided. 
• Possible intrusion of dirt in the pump is not acceptable as the reason for defective high-pressure pumps. The warranty claim will be rejected. 

Information 

• Do not bend high-pressure lines. Always remove the high-pressure distributor ppe 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. 

1. Remove holder for cooling water tube -7-  . To do this, remove hexagon-head bolt -6-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Peripheral engine cooling water tubes

2. Remove protective plate for high-pressure pump -7-  . To do this, unscrew the three screws on the protective plate and remove it.
   Fig 1: High-Pressure Pump Components Location (Turbo Engine)

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   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

3. Disconnect high-pressure line -2-  and low-pressure line -4-  at the high-pressure pump and place a cloth underneath. Counter with an open-ended wrench while doing this. The tool > Nr.98-1 Pos.1 - open-ended socket ring wrench  with > Nr.98-1 Pos.2 - adapter  can be used if necessary.
4. Remove three union nuts -6-  .
5. Carefully remove the high-pressure pump from the cylinder head.

   To do this, you will need to overcome the resistance of the sealing ring. Carefully lever off high-pressure pump with a screwdriver >. Remove high-pressure pump by turning it.

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   Loosening high-pressure pump

   Turn the high-pressure pump slightly and pull off cable plug for flow control valve -arrow-  .

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   Cable plug for flow control valve

   The Oldham coupling between the intake camshaft and high-pressure pump remains in the camshaft because of a loss preventer -1-  The Oldham coupling has symmetrical chamfers for the drivers -2-  on the high-pressure pump.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Oldham coupling for camshaft