Removing and installing high-pressure pump (engine codes BKS, BUN) — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Renewed: seals

🔧 Engine codes this applies to

📋 Procedure

1. Remove engine cover.
2. ⚠ Observe rules for cleanliness when working on the injection system . — Remove upper part of intake manifold .
3. Unscrew union nuts (1…4) and remove high-pressure lines.
4. Remove toothed belt for high-pressure pump .
5. Loosen central nut (1) for high-pressure pump shaft using counterhold3036.

6. Remove damper weight.
7. Use puller T40064 to pull off belt sprocket for high-pressure pump.
8. Disconnect fuel supply line (2) and fuel return line (1) from high-pressure pump and move lines clear to side.
9. Disconnect fuel supply line (2) and fuel return line (1) from high-pressure pump and move lines clear to side.
10. Unscrew bolts (1 … 4).
11. Unscrew bolts (1) and (3).
12. Disconnect electrical connector (2)
13. Carefully pull toothed belt guard in direction of (arrow) and remove high-pressure pump upwards. [Note: If the fuel pressure regulating valve N276 or the high-pressure pump have been changed, the learnt values for the regulating valve must be reset using the vehicle diagnosis testerin guided functions; Resetting learnt values for fuel pressure regulating valve.] [Note: Renew seals and gaskets.Hose connections and hoses for charge air system must be free of oil and grease before assembly.Secure all hose connections with hose clips (same as original equipment) Parts catalogue.]
14. ⚠ The high-pressure pump must first be filled with fuel before the engine is started. The high-pressure pump must not be allowed to run while still empty. — Tighten union nuts on high-pressure lines hand-tight. Ensure that connections are not under tension.
15. Tighten high-pressure lines:
16. To secure high-pressure line to high-pressure pump, use torque wrenchV.A.G 1331 with 17 mm socket T40055 or 14 mm open ring tool insertV.A.G 1331/8.
17. Install toothed belt for high-pressure pump .
18. Install upper part of intake manifold .
19. Bleed high-pressure pump .
20. Check fuel system for leaks .

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