1.4 TSI engine (EA111) · Mixture preparation – injection · High-pressure pump

Removing and installing high-pressure pump

Special tools and workshop equipment required

  • Torque wrench - V.A.G 1410-
  • Hose clamp pliers - VAS 6340-

Removing

Note safety precautions ⇒ 2 Safety precautions.

Observe rules for cleanliness ⇒ 3.1 Rules for cleanliness.

  • Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.

Prior to opening the high-pressure area, e.g. when removing the high-pressure pump, fuel rail, injectors, a fuel line, or the fuel pressure sender - G247-, the fuel pressure in the highpressure area must be reduced to a residual pressure of approx. 6 bar. The appropriate procedure is described in the chapter on releasing pressure in the high-pressure section ⇒ 2.3 Releasing pressure in high-pressure area.

  • Pull connector and fuel supply line -arrows- off high-pressure pump.
  • Remove wiring guide -2- and take clip -4- off high-pressure line.

When the high-pressure piston spring package loosens the high-pressure pump will leak and must be replaced.

  • Loosen union nuts -3- and -1- of high-pressure line.
  • Evenly unscrew securing bolts -arrows-.
  • Pull high-pressure pump -3- and roller tappet -1- out of camshaft housing.

Installing

When the high-pressure piston spring package loosens the high-pressure pump will leak and must be replaced.

Installation is carried out in the reverse order. When installing, note the following:

  • Slide roller tappet -1- into camshaft housing.
  • Insert new, lubricated O-ring -2- in groove of high-pressure pump -3-.
  • Place high-pressure pump -3- onto camshaft housing.
  • Screw in securing bolts -arrows- by hand until bolt heads are seated on flange.
  • Tighten securing bolts -arrows- evenly until flange is seated on camshaft housing.

Specified torque: 20 Nm

  • Tighten union nuts of high-pressure line -1- and -3- hand-tight.
  • Install wiring guide -2- and fit clip -4- on high-pressure line.

Specified torque of wiring guide securing bolt: 8 Nm

  • Tighten union nut -1- of high-pressure line to 18 Nm.
  • Tighten union nut -3- of high-pressure line to 18 Nm.
  • Secure fuel supply line and connector -arrows- on high-pressure pump.