High Pressure Fuel Pump

Special tools and workshop equipment required 

• Counterhold - Camshaft Gear T10051
• Union Nut Socket T40055
• Puller - Pulley T40064
• Puller - Pulley - Pressure Pad T40064/1
• Torque Wrench 1331 5-50 Nm VAG 1331
• Torque Wrench 1331 Insert - Reversible Ratchet VAG 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-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the spring clamps -3 and 4- using the 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 or contaminants.

-- 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 Differential Pressure Sensor -G505- connector -B- and the Fuel Pressure Sensor -G247- connector -C-.

Fig 3: Disconnecting Fuel Injector Connectors

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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 Counterhold - Camshaft Gear T10051 and remove the nut -1-.

Fig 4: Identifying Counter-Holder T10051 On High Pressure Fuel Pump Hub And Nut

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-- Position the Puller - Pulley T40064 with the Puller - Pulley - Pressure Pad T40064/1 and the Puller - Pulley - Socket Head Bolt T40064/2 as shown in the graphic below 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 High Pressure Fuel Pump Bolts

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-- Remove the high pressure fuel pump.

Installing

Install in the reverse order of removal. 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 1331 5-50 Nm VAG 1331 with the Torque Wrench 1331 Insert - Reversible Ratchet VAG 1331/1 and the Union Nut Socket T40055 to tighten the high pressure lines.

Fig 7: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 Mm T40055

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Tightening Specifications

• Refer to TOOTHED BELT DRIVE OVERVIEW
• Refer to 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 .