S8 High Pressure Fuel Pump
Product Information: High-Pressure Pump
The high-pressure pump is an essential component of the fuel
system in vehicles with engine codes CGTA/CTFA. The fuel system is
pressurized, and there is a risk of injury as fuel may spray out.
Therefore, it is crucial to wear safety goggles and protective
gloves while removing or installing the high-pressure pump. The
connections of the high-pressure pipe must not be damaged, and it
should not be attempted to bend the high-pressure pipe to a
different shape.
Special Tools and Workshop Equipment Required:
- Wrench, 21 mm -T40263-
- Turning over tool -T40272-
Product Usage Instructions: Removing and Installing
High-Pressure Pump
Step 1: Wear safety goggles and protective
gloves before starting.
Step 2: Open the engine cover panel before
removing the high-pressure pump. It is not permissible to start or
drive the vehicle with the bonnet closed if the engine cover panel
is not fitted.
Step 3: Locate the high-pressure pump. For
vehicles with engine codes CGTA/CTFA, it is located on cylinder
bank 1 (right-side). For all other engines, it is located on
cylinder bank 1 (right-side).
Step 4: Release pressure from the fuel system
by wrapping a clean cloth around the connection and opening it
carefully.
Step 5: Remove the fuel hoses from the
high-pressure pump.
Step 6: Remove the high-pressure pump using a
wrench, 21 mm -T40263-.
Step 7: Install the new high-pressure pump,
ensuring not to bend the high-pressure pipe to a different
shape.
Step 8: Fit new O-ring and secure all hose
connections with the correct type of hose clips (same as original
equipment) from the electronic parts catalogue.
Step 9: Use a turning over tool -T40272- to
align the semi-circular recess -arrow A- with a semi-circular
recess -arrow B- on the vibration damper.
Step 10: Tighten all connections according to
the tightening torques mentioned in the Exploded view –
high-pressure pump chapter.
Step 11: Close the engine cover panel before
driving the vehicle. It is not permissible to start or drive the
vehicle with the bonnet closed if the engine cover panel is not
fitted.
Removing and installing high-pressure pump
Removing and installing high-pressure pump
Special tools and workshop equipment required Wrench, 21 mm -T40263-
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Turning-over tool -T40272Removing Remove engine cover panel Chapter.
WARNING Danger of fire and damage if the engine cover panel is not fitted.
The engine cover panel must always be fitted before the bonnet is closed. If the engine cover panel is not fitted, it is not permissible to start or drive the vehicle with the bonnet closed.
Note Do not hold onto or pull on plunger of highpressure pumps. Cylinder bank 1 (right-side), vehicles with engine codes CEUA/CTGA: Release hose clips -arrows- and remove
air pipe.
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Removing and installing high-pressure pump
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Cylinder bank 1 (right-side), vehicles with engine codes CGTA/CTFA:
Release hose clips -arrows- and remove air pipe (right-side).
Cylinder bank 1 (right-side), all engines:
Remove bolts -arrows- and push wiring guide -1- slightly to right side.
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Removing and installing high-pressure pump
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Unplug electrical connector -1-. Release hose clips -2 and 4- and detach
fuel hoses.
WARNING The fuel system is pressurised. Risk of injury as fuel may spray out.
Wear safety goggles. Wear protective gloves. Release pressure (wrap clean cloth around connection and open connection carefully).
Wrap clean cloth around connection, remove union nuts -3- and press highpressure pipe to one side.
Remove bolts -arrows-. Cylinder bank 2 (left-side): Unplug electrical connectors -3-. Release hose clip -4- and detach fuel hose.
WARNING The fuel system is pressurised. Risk of injury as fuel may spray out.
Wear safety goggles.
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Removing and installing high-pressure pump
Wear protective gloves. Release pressure (wrap clean cloth around connection and open connection carefully).
Wrap clean cloth around connection, remove union nuts -2- and press highpressure pipe to one side.
Remove bolts -1- and -arrows-.
Both sides (continued):
Carefully pull out high-pressure pump. It is possible that the roller tappet may remain lodged inside.
Note
Do not attempt to bend high-pressure pipe to a different shape.
Installing
Note
Do not hold onto or pull on plunger of highpressure pump. Fit new O-ring. Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue. The connections of the high-pressure pipe must not be damaged. Do not attempt to bend high-pressure pipe to a different shape.
Check roller tappet -1- for damage and renew if necessary.
Lightly lubricate roller tappet with oil and insert it so that lug -arrow A- slides into guide notch -arrow B-.
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Removing and installing high-pressure pump
Disconnect vacuum hose -1-. Unscrew bolts -3- and remove vacuum
reservoir -2-.
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Fit turning-over tool -T40272- onto wrench (21 mm) -T40263-.
Position adapter on bolts of vibration damper.
Semi-circular recess -arrow A- on turning over tool -T40272- must point to semicircular recess -arrow B- on vibration damper.
Note
Disregard notch on turning-over tool -T40272 -.
Rotate crankshaft in direction of normal engine rotation -arrow- using wrench (21 mm) -T40263- and turning over tool T40272-, and at the same time press roller tappet into cylinder head until it reaches lowest point.
Remaining installation steps are carried out in reverse sequence; note the following:
Install high-pressure pipe Chapter.
Install air ducts with screw-type clips Chapter.
Check fuel system for leaks Chapter.
WARNING
Danger of fire and damage if the engine cover panel is not fitted.
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The engine cover panel must always be fitted before the bonnet is closed. If the engine cover panel is not fitted, it is not permissible to start or drive the vehicle with the bonnet closed.
Tightening torques
Chapter ,,Exploded view – highpressure pump”
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