High Pressure Fuel Pump

Special tools and workshop equipment required 

• Camshaft Gear Counter-Holder T10051
• Socket T40055
• Puller T40064
• Pressure Pad for T 40064 Tool T40064/1
• Torque Wrench (5-50 Nm) V.A.G 1331
• Ratchet, Reversible V.A.G 1331/1
• Hose Clip Pliers VAS 6362
• Engine Bung Set VAS 6122

Requirements 

• Ignition is turned off.
• Engine must be cold.

Removing 

-- Remove the toothed belt from the camshaft and the high pressure fuel pump. Refer to TOOTHED BELT .

-- Disconnect the fuel temperature sensor -G81- connector -1- and the fuel metering valve -N290- connector -2- on the high pressure fuel pump.

Fig 1: Identifying Fuel Temperature Sensor -G81- Connector -1-, Fuel Metering Valve -N290- Connector -2- And Spring Clamps -3 / 4-

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-- Loosen the spring clamps -3 and 4- using hose clip pliers VAS 6362 and disconnect the fuel lines from the high pressure fuel pump.

-- Seal the lines so that the fuel system is not contaminated by Dirt, etc.

-- Loosen the high pressure line and fuel line bolts -arrows- on the intake manifold.

Fig 2: Identifying Fuel Line Bolts On Intake Manifold

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-- Remove the protective strip, if equipped.

-- Disconnect the fuel injector connectors -A-, the exhaust pressure sensor 1 -G450- connector -B- and the fuel pressure sensor -G247- connector -C-.

Fig 3: Identifying Connector -C- From Fuel Pressure Sensor

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-- Remove the coolant line bolts -arrows- from the intake manifold and lay the line in front of the intake manifold.

-- Unclip the wiring harness from the wiring guide for the glow plugs.

-- Disconnect the glow plug connectors. Refer to GLOW PLUG CONNECTOR, DISCONNECTING AND CONNECTING .

-- Remove the high pressure line between the high pressure fuel pump and fuel rail.

-- Remove the toothed belt sprocket from the high pressure fuel pump.

-- Counter-hold the high pressure fuel pump hub using the camshaft gear counter-holder T10051 and remove the nut -1-.

Fig 4: Identifying Counter-Holder T10051 On High Pressure Fuel Pump Hub To Remove The Nut

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-- Position the puller T40064 with the pressure pad for T40064 tool T40064/1 as illustrated and remove the hub from the high pressure fuel pump. Counter-hold with a 24 mm open end wrench, if necessary.

Fig 5: Identifying Puller T40064 Positioned To Remove Hub From High Pressure Fuel Pump

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-- Remove the high pressure fuel pump bolts -arrows-.

Fig 6: Identifying Removal Of High Pressure Fuel Pump Bolts

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-- Remove the high pressure fuel pump.

Installing 

Install in reverse order of removal. When doing this note the following:

• Make sure no contaminants enter the fuel system when installing the high pressure fuel pump.
• Only remove the sealing plugs right before installing the fuel lines.
• Do not change the angles of the high pressure lines
• Make sure lines connections are securely fastened.
• Do not swap supply and return lines.

-- Tighten the union nuts for the high pressure lines by hand.

-- Make sure the high pressure lines are seated free of stress.

-- Use the torque wrench (5-50 Nm) V.A.G 1331 with the ratchet, reversible V.A.G 1331/1 and the socket T40055 to tighten the high pressure lines.

Fig 7: Identifying Socket T40055 At particles To Torque Wrench (5-50 Nm) V.A.G 1331 To Tighten Union Nuts

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Tightening Specifications 

• TOOTHED BELT OVERVIEW
• FUEL RAIL AND INJECTORS OVERVIEW 

-- Install and tension the toothed belt. Refer to TOOTHED BELT .

-- Fill the fuel system. Refer to FUEL SYSTEM, FILLING AND BLEEDING .