Table of contents: Removal ↓ Installation ↓
Parts and units of high pressure pump 1. Holder of additional units; 2. Bolt: 2 pcs.; replace; 20 Nm + 180°; 3. Hub: use the counter support "T10051" to loosen and tighten; to remove, use the puller "T40064"; 4. High pressure pump toothed belt pulley; 5. Bolt: 3 pcs.; replace; 20 Nm; 6. Nut: 95 Nm; 7. Bolt: replace; 20 Nm + 45°; 8. High pressure pump: with fuel metering valve "N₂90" (do not open); after replacement, it is necessary to refuel (it is imperative to avoid dry running); after replacing the high-pressure pump or the fuel pressure regulating valve "N₂76", it is necessary to carry out a repeated adaptation; 9. Fuel supply hose; 10. Return fuel hose; 11. High pressure line: between the high pressure pump and the fuel rail; install freely;lubricate the threads of the union nuts with clean oil; 25 Nm
Note: High-pressure lines can be reused after the following checks. Check the sealing cone for deformations and cracks. The opening must not be deformed, narrowed or damaged. Corroded lines must not be reused.
Removal
Caution! Risk of malfunction due to contamination. To avoid dry running of the high-pressure fuel pump (very tight tolerances) and in order to quickly start the engine after replacing parts, the following points must be observed. When removing or replacing parts/components of the fuel system, the first filling of the fuel system must be carried out between the fuel tank and the high-pressure fuel pump. After removing or replacing the fuel pump, fuel line (between tank and high pressure fuel pump) or fuel filter, it is necessary to bleed the fuel system before the first start of the engine. After removing or replacing the high-pressure fuel pump, it is necessary to bleed the fuel system before the first start of the engine.
Remove the toothed belt from the camshaft and high-pressure pump. Unscrew bolt "2" and union nuts "1 and 3", remove the high-pressure line.
Unscrew bolts "1 and 3". Remove the fuel hoses by loosening the hose clamps "2". Pull the fuel lines up from the cylinder head cover and push them aside. Do not take "Pos. 4" into account.
Disconnect the electrical plug connection "arrow" on the fuel metering valve "N₂90".
Unscrew the bolts of the "arrow" of the high-pressure pump toothed belt gear using the XZN 10 "T10385" attachment.
Unscrew nut "1" on the hub of the high-pressure fuel pump, to do this, hold it using the support "T10051".
Install the puller "T40064" with the mandrel "T40064/1" and the pin "T40064/2", as shown in the figure, and remove the bushing from the high-pressure pump. If necessary, hold it with a 24 spanner from turning.
Unscrew the high-pressure pump "arrow" mounting bolts. Carefully remove the high-pressure fuel pump.
Installation
Installation in reverse order, note the following. Install the toothed belt of the high-pressure pump. Install the high-pressure line. Before starting the engine for the first time, fill the high-pressure pump with fuel. The high-pressure pump must not run dry. Risk of destruction of the high-pressure pump when running dry. After replacing the high-pressure pump or the fuel pressure regulating valve "N₂76", adaptation must be carried out. The procedure is described in the Guided Fault Finding or in the Guided Functions, for this use the -Fahrzeugdiagnosetester-.