High Pressure Pump: Installing

Installation is in reverse order of removal, note the following:

NOTE:

High pressure line connections must not show any signs of damage.

Do not change the angles of the fuel lines.

Never bend any of the fuel line mounting clamps.

If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

-- Replace O-ring for the high-pressure pump.

-- Check plunger -1- for damage and replace it if necessary.

Fig 1: Checking Plunger

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-- Coat plunger with oil and insert it with the tab -arrow A- in the guide -arrow B-.

NOTE:

To insert the high pressure pump, the roller tappet must be at its lowest point.

-- Rotate crankshaft in the direction of engine rotation at the vibration damper bolt while pressing the roller tappet into the cylinder head until it reaches the deepest point.

-- Only lift the high pressure line slightly to insert the high pressure pump.

-- Install the high pressure pump into the housing.

-- Tighten bolts -arrows- by hand up to the flange.

Fig 2: Identifying High-Pressure Fuel Pump Components

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-- Tighten bolts diagonally to the tightening specification (approximately 1 turn until the bolts contact the high pressure pump).

NOTE:

Tightening on just one side (bending) can damage the pump.

Tightening Specifications. Refer to HIGH PRESSURE PUMP OVERVIEW .

-- Tighten fuel supply line union nut -5- by hand. Align so it is free of stress.

-- Connect fuel supply hose -2-.

-- Tighten bolts -3 and 4- on the retaining clamps.

Fig 3: Identifying High-Pressure Fuel Pump Components

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-- Connect connectors -1 and 6-.

-- Tighten high pressure line to the tightening specifications. Refer to Figure

Fig 4: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench VAS1331 With Ratchet VAS1331/1 And Socket 14 mm 3150

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-- Install protective plate -1-.

Fig 5: Identifying Nuts -Arrows- And Protective Plate -1-

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-- Install lower section of the air filter housing. Refer to LOWER AIR FILTER HOUSING .

NOTE:

Check fuel system for leaks.