Removing and Installing High-Pressure Pump
Removing And Installing High-pressure Pump
Technical values
Preliminary work
1. Disconnect the battery.
2. Drain coolant.
3. Remove housing for coolant regulator
Removal
Removing high-pressure pump
Component overview
1. Disconnect supply hose for coolant pump.
1.1. Open the spring band clamp -2- and pull off coolant hose -1-.
2. Remove coolant pipe.
2.1. Loosen Torx screws (M6 x 12) -1- and remove coolant pipe -2-.
3. Remove heat protection panel for high-pressure pump
3.1. Disconnect cable plug for flow control valve -2- and unclip cable -1-.
3.2. Unscrew three Torx screws (M6 x 12) -3- and remove heat protection panel -4-.
4. Remove cover for high-pressure pump.
4.1. Unscrew Torx screws M6 x 25 -1- and M6 x 40 -2-.
4.2. Guide out cover for high-pressure pump.
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapours.
- Attach warning sign in a clearly visible position.
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapours.
- Attach warning sign in a clearly visible position.
5. Remove fuel lines for high-pressure pump.
5.1. Loosen union nut on fuel low-pressure line -1-.
5.2. Loosen union nut on fuel high-pressure line -2-.
6. Remove high-pressure pump.
6.1. Unscrew Torx screws (M6 x 25) -3- used to secure the high-pressure pump.
6.2. Remove high-pressure pump.
Installation
Installing high-pressure pump
WARNING:
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
- Perform leak test.
Tightening sequence for high-pressure pump
INFORMATION: Before installing the high-pressure pump, check the position of the drivers and move them into installation position by hand if necessary.
1. Fit high-pressure pump.
1.1. Check sealing ring on high-pressure pump and replace it if necessary.
1.2. Position high-pressure pump.
1.3. Screw in Torx screws (M6 x 25) -1 and 2- and tighten to the prescribed tightening torque.
INFORMATION:
- A leak test must always be performed in the high-pressure area after opening the fuel system.
- This is particularly important if components are disassembled and replaced.
- The threaded connections of the fuel lines must be coated with OKS 1700 lubricant (Part no. 000.043.207.36) before being screwed back on again.
- The tightening specifications must be strictly observed.
- Blow residual fuel out of the lines and high-pressure pump (into a fuel-resistant container or cloth) using compressed air before installation.
2. Fit fuel lines for high-pressure pump.
2.1. Dip union nuts for fuel lines into the OKS 1700 lubricant and coat screw sockets for high-pressure pump with a brush.
2.2. Tighten union nut on fuel high-pressure line -2-. - Tightening torque: 20 Nm (15 ftlb.)
2.3. Tighten union nut on fuel low-pressure line -1-. - Tightening torque: 20 Nm (15 ftlb.)
3. Perform leak test.
4. Fit cover for high-pressure pump.
4.1. Guide in cover for high-pressure pump.
4.2. Screw in Torx screws M6 x 40 -3- and M6 x 25 -4 and 5- and tighten to the prescribed tightening torque.
5. Fit heat protection panel for high-pressure pump.
5.1. Position heat protection panel -4- , screw in three Torx screws (M6 x 12) -3- and tighten to the prescribed tightening torque.
5.2. Insert cable plug for flow control valve -2- and clip in cable -1-.
6. Fit coolant pipe.
6.1. Check sealing rings on coolant pipe and replace them if necessary.
6.2. Position coolant pipe -2- , screw in Torx screws (M6 x 12) -1- and tighten to the prescribed tightening torque.
7. Fit supply hose for coolant pump.
7.1. Push on coolant hose -1- and fit the spring band clamp -2-.
Subsequent work
1. Install housing for coolant regulator.
2. Fill in coolant and bleed the cooling system
3. Connect the battery.
4. Start the system for the first time.
5. If the high-pressure pump was replaced, a high-pressure adaptation is required.