Volkswagen Rabbit/GTI/Jetta/GLI MkV DIY & FAQ

DIY: High pressure fuel pump removal/installation & cam/follower inspection

**** Disclaimer/Warning: I’m not responsible for any damage you do to your car following this DIY. I’m also not responsible for injuries you may suffer. Goggles and gloves are a MUST for this job. The HPFP and rail can contain fuel pressurized to 120bar!!! Even a standard 3-4bar fuel rail is enough to inject fuel through your skin and directly into your blood… resulting in blood poisoning and death. Caution and safety precautions are of the utmost importance! ****

Tools Required (this may vary if you have a different intake):
Intake removal -
Flathead screwdriver
10mm socket & small socket wrench
Pump removal -
13mm box wrench
17mm box wrench
M8 triple square socket
8mm box wrench
Electical tape
T30 torx key, or torx socket (& matching socket wrench)
Safety goggles/glasses
Gloves

Step 1:
Remove fuel pump fuse

Step 2:
Start the engine. Allow it to run out of fuel. Pop the hood, and allow the engine 20-30 minutes to cool (especially if you were driving recently). The HPFP get’s VERY HOT!

Step 3:
Remove intake, or engine cover depending on how your car is equipped.

Step 4:
Remove accordian hose from PCV to intake manifold. (blue arrows)
Disconnect main PCV line from PCV assembly. (green arrow)
Disconnect vac/boost tap (boost gauge/dv) to allow more room. (red arrow)

Step 5:
Place rag behind bleed valve. BE SURE TO WEAR YOUR SAFETY GOGGLES AND GLOVES FROM THIS POINT ON! Using the 13mm box wrench, unscrew the valve. Some fuel may hiss out; if this happens, just step back and let the pressure bleed off before you continue.

Step 6:
Disconnect wire harness from N276 on top of pump.

Step 7:
Reposition your rag behind the fuel lines below the pump. Using your 17mm box wrench, loosen the nut on the right-hand fuel line. Slide nut down out of the way.

Step 8:
Using the M8 triple square, 8mm box wrench, and some electrical tape… make yourself this little tool (this is the easiest way I found to reach the banjo bolt in the next step).

Step 9:
Use the tool you just put together to remove the banjo bolt from the left-hand fuel line. Make sure you don’t drop the bolt!

Step 10:
Use the T30 torx to remove the 3 fuel pump mounting bolts.

Step 11:
Make sure the fuel lines are free from the bottom of the pump, and pull it free from the cylinder head.

Step 12:
Disconnect the wiring harness (gray connector) from the low pressure sensor (on my pump it was flipped and not accessible until the pump was removed.

Step 13:
Cover the area you removed the pump from with a clean rag to prevent contamination.

Installation:
Install is the reverse of removal. Just make sure to oil this o-ring with clean engine oil before you put it back in place.

Torque specs-
T30 pump mounting bolts: 10Nm
Fuel line nut: 25Nm
Banjo bolt: 17Nm

Taking it a step further…
Many people have had fuel cut issues. Many have seen the TSB regarding the camshaft going bad and needing replacement. If you’ve had fuel cut issues, and you’d like to diagnose this for yourself… you can. After the HPFP is removed, you can slide your finger into the hole in the head and slide the cam follower out. You can then investigate for yourself if there are any signs of wear on either piece. From what I can tell, mine look ok.

Cam follower

Camshaft

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