Removing and installing high-pressure pump - engine code CAVD — VW

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

• Opens: coolant
• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• Turn crankshaft in direction of engine rotation to 1st cyl. TDC (do not drain coolant and do not remove sealing caps for camshafts).
• Catch escaping fuel in a cloth.
• When loosening union nuts, counterhold threaded connections on high-pressure pump and on lower part of intake manifold/fuel rail using a wrench.
• Moisten high-pressure pump roller tappet with clean engine oil.The high-pressure pump O-ring must always be renewed.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📐 46 workshop diagrams for CAVD

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar).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 high-pressure 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 of the fuel system”". — Remove engine cover panel .
2. Turn crankshaft in direction of engine rotation to 1st cyl. TDC (do not drain coolant and do not remove sealing caps for camshafts).
3. Remove intake connecting pipe .
4. Pull fuel supply line (right arrow) off high-pressure pump. [Note: Catch escaping fuel in a cloth.]
5. Remove wiring guide (2) and take clip (4) off high-pressure line. [Note: When loosening union nuts, counterhold threaded connections on high-pressure pump and on lower part of intake manifold/fuel rail using a wrench.]

6. Loosen union nuts (3) and (1) of high-pressure line.
7. Evenly unscrew securing bolts (arrows).
8. Pull high-pressure pump (3) and roller tappet (1) out of camshaft housing. [Note: Moisten high-pressure pump roller tappet with clean engine oil.The high-pressure pump O-ring must always be renewed.]
9. Slide roller tappet (1) into camshaft housing.
10. Insert new, lubricated O-ring (2) in groove of high-pressure pump (3).
11. Place high-pressure pump (3) onto camshaft housing.
12. Screw in securing bolts (arrows) by hand until bolt heads are seated on flange.
13. Tighten securing bolts (arrows) evenly until flange is seated on camshaft housing.
14. Tighten union nuts of high-pressure line (1) and (3) hand-tight.
15. Install wiring guide (2) and fit clip (4) on high-pressure line. [Note: When loosening union nuts, counterhold threaded connections on high-pressure pump and on lower part of intake manifold/fuel rail using a wrench.]
16. Tighten union nut (1) of high-pressure line to 18 Nm. — 18 Nm (13 lb-ft)
17. Tighten union nut (3) of high-pressure line to 18 Nm. — 18 Nm (13 lb-ft)
18. Secure fuel supply line and plug (arrows) on high-pressure pump.
19. Install intake connecting pipe and air filter .

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