High Pressure Fuel Pump: Removing: Procedure

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

-- Remove the toothed belt from the camshaft and the high pressure fuel pump TOOTHED BELT , Toothed Belt, Removing, Installing and Tensioning.

-- Disconnect the connector from the Fuel Temperature Sensor -G81- -1- and Fuel Metering Valve -N290- on the high pressure fuel pump -2-.

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

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-- Loosen the spring clips -3 and 4- with the Spring Clip Pliers VAS 6362 and disconnect the fuel lines at the high pressure fuel pump.

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

-- Loosen the high pressure line or fuel lines -arrows- on the intake manifold.

Fig 2: Identifying Fuel Line Bolts On Intake Manifold

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-- Remove the protective strip, if equipped -item 1-.

-- Remove the connector on the fuel injectors -A-, the Exhaust Pressure Sensor 1 -G450- -B- and the Fuel Pressure Sensor -G247- -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.

CAUTION: Always follow the procedure >>Glow Plug Connectors, Disconnecting and Installing<<. Refer to GLOW PLUG CONNECTORS, REMOVING AND INSTALLING .

-- Remove the glow plug connectors GLOW PLUG CONNECTORS, REMOVING AND INSTALLING .

-- Remove the high pressure line -item 21 between the high pressure fuel pump and rail element (high pressure reservoir).

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

-- Counterhold the high pressure fuel pump hub with the Counterhold Tool 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 T40064 with the Thrust Piece T40064/1 and Pin T40064/2 as shown and remove the hub from the high pressure fuel pump. Counterhold with a 24 mm open-end wrench if necessary.

Fig 5: Identifying Puller T40064, Pressure Pad T40064/1 And Pin T40064/2

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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.