1.2 TDI CR engine (EA189) · Mixture preparation – injection · High-pressure pump

Removing and installing high-pressure pump

Performing first fuel filling after installing high-pressure pump ⇒ 1.3 Filling/bleeding fuel system.

Caution

To prevent the high-pressure fuel pump from running while it is empty (very tight tolerances) and to ensure that the engine starts quickly after parts have been renewed, it is important to observe the following:

If fuel system components between fuel tank and fuel high-pressure pump are removed or replaced:
Basic setting “Checking fuel pre-supply pump” must be carried out to bleed fuel system.
If a fuel pump, fuel line (between fuel tank and fuel highpressure pump) or fuel filter is removed or replaced:
Basic setting “Testing fuel pre-supply pump” must be carried out »once« before first starting engine.
If the high-pressure fuel pump is removed or renewed, the basic setting “Checking fuel system pressurisation pump” must be performed »three times« before the engine is started for the first time.

Special tools and workshop equipment required

Counter-hold tool - T10051-
Puller - T40064-
Thrust piece - T40064/1-
Puller - T40064/2-
Torque wrench - V.A.G 1331-

»Carry out the following work sequence«

Removing

Remove engine cover panel ⇒ 3 Engine cover panel.
Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50; Body - front; Assembly overview - noise insulation

Pull off connectors -10, 11 and 12-.

10 Hall sender - G40-
11 Fuel metering valve - N290-
12 Fuel temperature sender - G81- in fuel supply line

Unscrew coolant return line bolts -arrows-.
Lay coolant return line to side.

If the high-pressure pump is not replaced:

Collect escaping fuel with a cleaning cloth.

Pull off fuel hoses -1 and 6-. To do this, press the quick-release couplings onto the connections, press in the locking elements (keep pressed) and pull the quick-release couplings off.

If the high-pressure pump is replaced:

Pull fuel hoses -arrows- off the high-pressure pump.

Continuation for both work processes (replacing high-pressure pump/not replacing high-pressure pump):

Carefully release fuel return line -arrow- at high-pressure pump.
Carefully pull fuel return line out of high-pressure pump.

Detach high-pressure line -2- between fuel rail and high-pressure pump.
Remove charge air pipe »cold« side ⇒ 2.3.2 Removing and installing charge air pipe »hot« side.
Remove poly V-belt ⇒ 13 – Crankshaft group.
Remove toothed belt from camshaft and high-pressure pump ⇒ 2.1.1 Removing and installing engine bracket.

Unscrew bolts -1-.
Remove toothed belt pulley from high-pressure pump.

Unscrew nut -1- at hub of high-pressure pump. To do this, counterhold with counterhold - T10051-.

Place puller - T40064- with thrust piece - T40064/1- and puller - T40064/2- in position as shown and pull hub off high-pressure pump. Counterhold with an 24 mm open-end spanner.

Unscrew securing bolts -arrows- of high-pressure pump.
Remove high-pressure pump.

Installing

Install in reverse order.

The bolts for high-pressure pump must be replaced.
Specified torques: assembly overview - fuel rail ⇒ 3.5 Removing and installing high-pressure lines.
Specified torques for toothed belt drive: ⇒ 2 Toothed belt drive

Filling/bleeding high-pressure pump and fuel system ⇒ 1.3 Filling/bleeding fuel system.