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VW CR Pump Start/StopVW CR Pump without ITPRepair instructions

Diesel Common Rail Pump 29

1000

0825

200

06.2

017

© Continental Trading GmbH2

VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump

Continental Trading GmbH Sodener Straße 9 65824 SchwalbachGermanyTel: +49 6196 [email protected] – A Trademark of the Continental Corporation

The instructions and work steps listed in the repair instructions apply generally for both CR pump types VW CR Start/Stop and VW CR without ITP. Work steps that relate to only one pump type are marked accordingly.

3

VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump

Table of contents

1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Qualification of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.3 Symbols in these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2 Conditions for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1 Work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.3 Materials and replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.4 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.5 Repair scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3 Cleaning before the repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5 Dismantling the high pressure pump (without ITP) . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.1 Clamping the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

5.2 Removing the Volume Control Valve (VCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

5.3 Removing the high pressure connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

5.4 Removing the high pressure elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

5.5 Removing the high pressure pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

5.6 Removing the camshaft and excenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.7 Removing the shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

6 Component check (without ITP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

6.1 Measuring the camshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

6.2 Measuring the excenter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

6.3 Measuring the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

6.4 Measuring the high pressure pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

6.5 Testing the VCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

7 Assembling the high pressure pump (without ITP) . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

7.1 Installing the shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

7.2 Installing the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

7.3 Installing the high pressure pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

7.4 Installing high pressure elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

7.5 Installing the high pressure connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

7.6 Installing the VCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

7.7 Attaching the DRS type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38



8 Dismantling the high pressure pump (Start/Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

8.1 Clamping the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

8.2 Removing the Volume Control Valve (VCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

8.3 Removing the high pressure connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

8.4 Removing the high pressure elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

8.5 Removing the high pressure pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

8.6 Removing the ITP (Gerotor) and control plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

8.7 Removing the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

8.8 Removing the shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

9 Component inspection (Start/Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

9.1 Measuring the camshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

9.2 Measuring the excenter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

9.3 Measuring the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

9.4 Measuring the control plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

9.5 Checking the Gerotor, high pressure pump cover and control plate . . . . . . . . . . . .53

9.6 Testing the VCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

10 Assembling the high pressure pump (Start/Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

10.1 Installing the shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

10.2 Installing the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

10.3 Installing the control plate and ITP (Gerotor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

10.4 Installing the high pressure pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.5 Installing high pressure elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

10.6 Installing the high pressure connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

10.7 Installing the VCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

10.8 Attaching the DRS type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

11 Testing on approved pump test stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

11.1 Checking the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

11.2 Placing on the design cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

12 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

13 Repair parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

14 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Table of contents

5


Repairing the high pressure pump

1 Safety instructions

Read the following safety instructions carefully and completely.

Do not start with the repair work until you have understood all safety instructions and procedures.

Observe the instructions in accordance with the safety data sheets of the media being used.

1.1 Working on the fuel system

For all work on the diesel fuel system and on the high pressure pump, observe the regulations and conditions:

• of the vehicle manufacturer

• of the accident prevention

• of the responsible health authorities

• of the responsible professional association

For tests on the test stand:

• Wear safety goggles and protective clothing.

• Do not put your hands into the area of a leakage in the high pressure fuel system.

• Always stay out of the reach of any fuel jet. This could cause serious injuries.

Diesel fuel under pressure is flammable.

• Do not smoke in the vicinity of the high pressure system.

• Keep flame or sparks away.

• Observe the operating instructions for hazardous materials.

1.2 Qualification of the personnel

All work that is performed on the fuel system must be carried out by qualified specialists.Qualified specialists are people who have been trained and authorised by the manufacturer to carry out maintenance and repair work on the diesel fuel system.



Symbol Signal word Meaning

WARNING Signifies a danger which can lead to death or severe injuries

CAUTION Signifies a danger which can lead to minor or moderate injuries

- ATTENTION Makes you aware of possible material damage

- Practical tip or reference

1.3 Symbols in these instructions

7


2 Conditions for repair

2.1 Work area

• The work area must be clean and orderly.

• Wear clean, dust-free clothing in the work area.

• The high pressure pump may only be disassembled and assembled in a clean-room environment.

• Parts in repair must be transported and stored so that they are protected from dust.

2.2 Tools

• Use only torque wrenches that have been regularly inspected.

Always comply with the tightening torques for:

• High pressure control valve

• Volume control valve

• High pressure elements

• High pressure pump cover (CR pump without ITP)

• High pressure pump cover (CR Pump Start/Stop)

• High pressure pump connections

Special tools, see chapter 12

2.3 Materials and replacement parts

• Always use original replacement parts and repair kits.

• Always use new seals and screws for the high pressure element.

2.4 Markings

• Do not use paint sticks, etc. to make marks.

• Use an alcohol-based felt-tipped pen.

2.5 Repair scope

The scope of the repair is determined from the result of the error analysis.

9


3 Cleaning before the repair

Before all work on the high pressure pump, perform a thorough external cleaning of the pump. Doing so will prevent dirt particles from getting into the high pressure system.

There can be residual amounts of diesel fuel and test oil in the pump before and after the repair and inspection.

Before sealing the connections, the pump must be turned in all directions to allow any residual liquids to drain out and be collected for proper disposal.

The connections of the high pressure pump must be sealed with plugs before the cleaning.

Attach protective cap for the shaft thread.

ATTENTIONTo prevent damage to the fuel system, do not use fuel line cleaners or metal coating agents.

ATTENTIONTo prevent damage to the diesel common rail pump, do not carry the pump by the connectors, line connections or by the housings of the volume control valve and high pressure control valve.

ATTENTIONDo not flush the pump with cleaning agents.

11


VW CR Pump Start/Stop / AWP2 India

VW CR Pump without ITP

4 Identification

The only difference between the VW Start/Stop and VW AWP2 India is the camshaft.

The Start/Stop version can be seen on the additional outward-facing cover.

13


5 Dismantling the high pressure pump (without ITP)

Exploded view of VW CR Pump without ITP



All subsequently described activities refer to work on the removed high pressure pump .

5.1 Clamping the high pressure pump

Have the following ready for the disassembly:

• Basic mounting holder for CR pumps (1)• Basic shaft holder CR pump (2)• Pump holder (3)

1. Assemble the basic mounting holder for CR pumps, basic shaft holder CR pump, and pump holder.

2. Clamp high pressure pump onto pump holder.

D CAUTION Risk of injury by crushing or bumping when

working on the disassembled pump! • Affix the mounting device firmly so that it can not

slip, e.g. to a workbench. • Wear safety shoes.

ATTENTIONThe pump holder 2910000417600 is suitable for the attach-ment of VW CR pumps and DV6C CR pumps. For securing VW pumps, the pump holder must look as shown.

Fig. 5-1a: Basic mounting equipment with pump holder

Fig. 5-2: High pressure pump clamped

1

2

3

Fig. 5-1b: Pump holder

15


5.2 Removing the Volume Control Valve (VCV)

Have the following ready for the removal:

• Hexagon insert 3/8“, extra long (4 mm)• Special pliers for filter removal/installation

1. Loosen VCV using hexagon insert 3/8“, extra long (4 mm). ATTENTION Be sure that you do not damage the return flow nozzle and high pressure connection when loosening the VCV screws.

2. Pull the VCV out of the high pressure pump.

3. Pull the filter out of the high pressure pump cover using special pliers.

Fig. 5-3: Removing the VCV

Fig. 5-4: Special pliers with filter

Check the filter for cleanliness and replace, if necessary.

ATTENTIONIn certain versions of the CR high pressure pump, no filter is installed at the factory.A retrofitting of the filter is not possible!



5.3 Removing the high pressure connection

1. Loosen and remove the high pressure connection.

ATTENTION Do not damage the threads of the high pressure connection.

2. Remove pinhole aperture in the high pressure connection.

ATTENTION Use plastic tweezers. Do not damage the sealing surface of the high pressure connection.

Fig. 5-5: High pressure pump connection

Fig. 5-6: Pinhole aperture in the high pressure connection

17


5.4 Removing the high pressure elements

D CAUTION The high pressure elements are under spring

force . Parts that pop out can cause injury! Counterhold the high pressure elements when loosening and removing the attachment screws.

1. Remove the design cover.

2. Loosen and remove the attachment screws (Torx 45) of the first high pressure element.

3. Remove the high pressure element completely.

4. Remove all sealing rings using a suitable tool (e.g. plastic tweezers). (4 pcs. 1–4, Fig. 5-8 b)

Fig. 5-7: Design cover

Fig. 5-8a: High pressure element Fig. 5-8b: High pressure element sealing rings

1

2

4

3



5. Repeat work steps 2, 3, and 4 for the second high pressure element.

ATTENTIONPiston and high pressure element are a pair. They may not be replaced individually.

ATTENTIONDo not mix up the high pressure element pairing to excenter position. Mark the high pressure element, pump housing, and excenter so that the assignment/position is given when assembling.

Fig. 5-9: High pressure elements

To better facilitate removing the second high pressure element, you can swivel the mounting device on the longitudinal axis.

19


5.5 Removing the high pressure pump cover

1. Tilt the high pressure pump in the mounting device towards the rear by 90°.

2. Loosen and remove the attachment screws (4 pcs., Torx 30) of the high pressure pump cover.

3. Carefully lift out the high pressure pump cover.

4. Use plastic tweezers to remove the sealing rings (5+6, 2 pcs.) of the high pressure pump cover.

Fig. 5-10: High pressure pump cover

To better facilitate removing the high pressure pump cover, you can tilt the mounting device.

Fig. 5-11:

6

5



5.6 Removing the camshaft and excenter

1. To protect against mechanical damage to the shaft threads, ensure that the thread protection cap is installed.

2. Pull the camshaft and excenter out of the high pressure pump housing.

3. Use plastic tweezers to remove the sealing ring (7, 1 pc.) inside the high pressure pump.

ATTENTIONMark the position of the excenter so that it can be installed again in the same position.

Fig. 5-12: Shaft with excenter

Fig. 5-13: Camshaft with bearing

7

21


5.7 Removing the shaft sealing ring

1. Carefully remove shaft sealing ring using suitable pulling tool with rear grabber hooks.

ATTENTIONDo not damage the edges of the housing and the seating of the shaft sealing ring.

Fig. 5-14: Removing the shaft sealing ring

23


6 Component check (without ITP)

After dismantling the high pressure pump, the high pressure pump elements must be checked for wear and damage before assembling or replacing components.

Have the following ready for inspection and measure-ment:

• Inner precision instrument measuring range: 18–35 mm

• Outside micrometer measuring range: 25–50 mm

6.1 Measuring the camshaft bearing

Using an inner precision instrument, measure the bearing of the camshaft:

Nominal values: Max: 25.047 mm/Min: 25.017 mm

Fig. 6-1: Checking the camshaft bearing

Do not tilt the measuring equipment (inner precision instrument, outside micrometer) as this can lead to faulty results.

ATTENTIONIf the tolerance is exceeded, the high pressure pump must be replaced.



6.2 Measuring the excenter

Using an inner precision instrument, measure the bearing of the excenter:


ATTENTIONIf the tolerance is exceeded, replace the excenter with all high pressure elements as a set.

Fig. 6-2: Excenter bearing

25


6.3 Measuring the camshaft

Perform a visual inspection of the shaft for damage to the threads and for grooves caused by the shaft sealing ring.

Using an outside micrometer, measure the camshaft at the mating surface to the flange bearing:


Perform measurement at two points offset by 90°.

ATTENTIONIf the tolerance is exceeded, the camshaft must be replaced.

Using an outside micrometer, measure the camshaft at the mating surface to the housing bearing:




Fig. 6-3: Camshaft (front)

Fig. 6-4: Camshaft (rear)



Using an outside micrometer, measure the cam of the camshaft:




6.4 Measuring the high pressure pump cover

Measure the high pressure pump cover. Using an inner precision instrument, measure the bearing.


Fig. 6-5: Camshaft Cam

Fig. 6-6: Measuring the high pressure pump cover

27


6.5 Testing the VCV

Test the electrical resistance of the VCV coil using an ohmmeter:

Nominal value: 2.4 Ohm +/– 0.25 Ohm

Fig. 6-7: Testing the VCV

29


7 Assembling the high pressure pump (without ITP)


7.1 Installing the shaft sealing ring

Have the following parts ready:

• New shaft sealing ring• Pressure pad VW/DV6C shaft sealing ring• Gasket kit cover

1. Carefully place new shaft sealing ring and pressure pad on the seat in the high pressure pump housing and align horizontally.

2. Using a suitable tool (e.g. lever press), press the shaft sealing ring until the pressure pad comes into contact with the high pressure pump housing. ATTENTION Shaft sealing ring is not seated flush with the high pressure pump housing but recessed by 0.5 +/- 0.3 mm. Special tool: Use pressure pad shaft sealing ring VW/DV6C

Fig. 7-1: High pressure pump housing with shaft sealing ring

Fig. 7-2: High pressure pump housing with pressure pad shaft sealing ring VW/DV6C



3. Insert the new sealing ring in the interior of the high pressure pump.

D CAUTION Risk of injury by crushing or bumping

when working on the disassembled pump! • Affix the mounting device firmly so that it cannot


7.2 Installing the camshaft Have the following ready for the installation:

• Inspected or new camshaft• Fit up aid camshaft VW/DV6C

Observe the following when inserting the camshaft: • Do not damage the sealing lip of the shaft

sealing ring.

• Do not wet the shaft sealing ring and camshaft with lubricants.

• The running-in procedure between sealing lip and camshaft occurs dry.

1. Insert the expanding side of the fit up aid at right angle to the shaft sealing ring.

Fig. 7-3: High pressure pump housing with inner shaft sealing ring

Fig. 7-4: Fit up aid for camshaft expanding side faces the shaft sealing ring

31


Fig. 7-6: Drive pin of the camshaft in fit up aid

Fig. 7-5: Fit up aid for camshaft shaft receiving side faces the shaft sealing ring

2. After waiting 5 seconds, quickly turn the fit up aid by 180° and carefully insert with shaft receiving side in the shaft sealing ring.

3. Insert camshaft inside high pressure pump housing in shaft receiving side of the fit up aid. Make sure that the drive pin is correctly seated!



Fig. 7-7: High pressure pump housing with inserted camshaft

4. Push the pump shaft with the excenter attached in one movement sequence against the fit up aid until the shaft rests in the high-pressure pump housing.

33


7.3 Installing the high pressure pump cover

Have the following ready for the installation:

• Inspected or new high pressure pump cover • Mounting screws • Torque wrench• Mounting screws• Gasket kit cover• Torque wrench

1. Provide high pressure pump cover with new sealing rings (5+6) and place onto high pressure pump housing.

2. Insert mounting screws of the high pressure pump cover (4 pc., Torx 30) and tighten slightly.

3. Tighten the mounting screws of the high pressure pump cover crosswise slightly and then tighten to the specified torque.

Tightening torque:Screw high pressure pump cover to high pressure pump housing: 12 Nm


Fig. 7-8: High pressure pump housing with high pressure pump cover

6

5



7.4 Installing high pressure elements


• Gasket kit high pressure element• Torque wrench

ATTENTIONNever install high pressure elements without gaskets.

ATTENTIONRisk of fire due to external leakage

Tilt the high pressure pump in the mounting device towards the front.

To insert the high pressure elements more easily, turn the camshaft until the flat side of the excenter is standing in the direction of the opening of the high pressure element (bottom dead centre).

1. Insert sealing ring low pressure side (1)

Fig. 7-10: Gasket kit high pressure element

Fig. 7-11: Sealing ring (low pressure)

1

4

2 3

1

35


Fig. 7-13: High pressure pump housing with high pressure element

Fig. 7-12a: Support ring (2) and sealing ring (3) (high pressure)

Fig. 7-12b: High pressure element with base gasket

2. Insert support ring (2) and sealing ring (3) high pressure side.

3. Place base gasket (4) onto seat surface of the high pressure element.

4. Carefully place on high pressure element (after turning the shaft to bottom dead centre); screw in all 4 screws with approx. 1 to 2 turns, then with ONE movement, press down high pressure element using suitable clamp-ing device.

5. Then tighten the four screws crosswise under pretension.

6. Repeat working steps 1–5 for second high pressure element.

To install the other two high pressure elements, swivel the mounting device on the longitudinal axis.

Tightening torque:Screw high pressure element at high pressure pump: 25 Nm

1

2

3

4



7.5 Installing the high pressure connection


• Torque wrench• High pressure connection repair kit

ATTENTIONNever install high pressure connection without the pinhole aperture. Without the aperture, the high pressure pump will malfunction. Leaks can occur if two apertures are used (possibly old and new).


1. Insert the aperture in the high pressure connection.

2. Insert high pressure connection and tighten slightly.

3. Tighten high pressure connection to the specified torque.

4. Attach protective cap for the high pressure connection.

Tightening torque: High pressure connection to high pressure pump: 30 +/– 2 Nm



37


Fig. 7-16: VCV with mounted filter

7.6 Installing the VCV


• Filter• VCV• Torque wrench• Hexagon insert 3/8“, extra long (4 mm)

1. Grease the sealing ring of the filter slightly (all-purpose grease).

2. Place filter onto VCV.

3. Join VCV with attached filter to high pressure pump flange and tighten.

Tightening torque:VCV to high pressure pump: 6 Nm

ATTENTIONIn certain versions of the CR high pressure pump no filter is installed at the factory. The installation of the VCV is done without filter. A retrofitting of the filter is not technically possible!

Fig. 7-17: Tightening the VCV



7.7 Attaching the DRS type plate


• DRS type plate

1. Clean surface.

2. Attach the DRS type plate.

3. Place a visible mark in the immediate vicinity of the original pump type plate using a centre punch.

The original pump type plate must remain visible on the pump.

Fig. 7-18: Position of the type plate

39


8 Dismantling the high pressure pump (Start/Stop)

Exploded view of VW CR Pump Start/Stop




8.1 Clamping the high pressure pump

Have the following ready for the disassembly:

• Basic mounting holder for CR pumps (1)• Basic shaft holder CR pump (2)• Pump holder (3)

1. Assemble the basic mounting holder for CR pumps, basic shaft holder CR pump, and pump holder.

2. Clamp high pressure pump onto pump holder.




ATTENTIONThe pump holder 2910000417600 is suitable for the attachment of VW CR pumps and DV6C CR pumps. For securing VW pumps, the pump holder must look as shown.

Fig. 8-1a: Basic mounting equipment with pump holder

Fig. 8-2: High pressure pump clamped

1

2

3

Fig. 8-1b: Pump holder

41


8.2 Removing the Volume Control Valve (VCV)

Have the following ready for the removal:

• Hexagon insert 3/8“, extra long (4 mm)• Special pliers for filter removal/installation

1. Loosen VCV using hexagon insert 3/8“, extra long (4 mm). ATTENTION Be sure that you do not damage the return flow nozzle and high pressure connection when loosening the VCV screws.

2. Pull the VCV out of the high pressure pump.

3. Pull the filter out of the high pressure pump cover using special pliers.

ATTENTIONIn certain versions of the CR high pressure pump, no filter is installed at the factory. A retrofitting of the filter is not technically possible!

Fig. 8-3: Removing the VCV

Fig. 8-4: Special pliers with filter

Check the filter for cleanliness and replace, if necessary.



8.3 Removing the high pressure connection

1. Loosen and remove the high pressure connection.

ATTENTION Do not damage the threads of the high pressure connection.

2. Remove pinhole aperture in the high pressure connection.

ATTENTION Use plastic tweezers. Do not damage the sealing surface of the high pressure connection.



43


8.4 Removing the high pressure elements

D CAUTION The high pressure elements are under spring

force . Parts that pop out can cause injury! Counterhold the high pressure elements when loosening and removing the attachment screws.

1. Remove the design cover.

2. Loosen and remove the attachment screws (Torx 45) of the first high pressure element.

3. Remove the high pressure element completely.

4. Remove all sealing rings using a suitable tool (e.g. plastic tweezers). (4 pcs. 1–4, Fig. 8-8 b)

Fig. 8-7: Design cover

Fig. 8-8a: High pressure element Fig. 8-8b: High pressure element sealing rings

1

2

4

3



5. Repeat work steps 2, 3, and 4 for the second high pressure element.

ATTENTIONPiston and high pressure element are a pair. They may not be replaced individually.

ATTENTIONDo not mix up the high pressure element pairing to excenter position. Mark the high pressure element, pump housing and excenter so that the assignment/position is given when assembling.

Fig. 8-9: High pressure elements

To better facilitate removing the second high pressure element, you can swivel the mounting device on the longitudinal axis.

45


8.5 Removing the high pressure pump cover

1. Tilt the high pressure pump in the mounting device towards the rear by 90°.

2. Loosen and remove the attachment screws (4 pcs., Torx 30) of the high pressure pump cover.

3. Carefully lift out the high pressure pump cover.

4. Use plastic tweezers to remove the sealing ring (1 pc.) of the high pressure pump cover.


To better facilitate removing the high pressure pump cover, you can tilt the mounting device.



8.6 Removing the ITP (Gerotor) and control plate

Gerotor must be installed aligned. Top and bottom side may not be mixed up. Mark position/orientation.

ATTENTIONThe Gerotor may not be damaged.

1. Lift off Gerotor (inner and outer rotor).

2. Pull control plate up and remove.

3. Remove O-ring of the control plate (1 pc.) using plastic tweezers.

4. Remove O-ring inside the high pressure pump housing (1 pc.) using plastic tweezers.

Fig. 8-11: Gerotor

Fig. 8-12: Control plate and high pressure pump housing

47


8.7 Removing the camshaft

1. To protect against mechanical damage to the shaft threads, ensure that the thread protection cap is installed.

2. Pull the camshaft and excenter out of the high pressure pump housing.

ATTENTIONMark the position of the excenter so that it can be installed again in the same position.

Fig. 8-13: Shaft with excenter

Fig. 8-14: Camshaft with bearing



8.8 Removing the shaft sealing ring

1. Carefully remove shaft sealing ring using suitable pulling tool with rear grabber hooks.

ATTENTIONDo not damage the edges of the housing and the seating of the shaft sealing ring.

Fig. 8-15: Removing the shaft sealing ring

49


9 Component inspection (Start/Stop)

After dismantling the high pressure pump, the high pressure pump elements must be checked for wear and damage before assembling or replacing components.

Have the following ready for inspection and measure-ment:

• Inner precision instrument measuring range: 18–35 mm

• Outside micrometer measuring range: 25–50 mm

9.1 Measuring the camshaft bearing

Using an inner precision instrument, measure the bearing of the camshaft:


Fig. 9-1: Checking the camshaft bearing

Do not tilt the measuring equipment (inner preci-sion instrument, outside micrometer) as this can lead to faulty results.

ATTENTIONIf the tolerance is exceeded, the high pressure pump must be replaced.



9.2 Measuring the excenter

Using an inner precision instrument, measure the bearing of the excenter:


ATTENTIONIf the tolerance is exceeded, replace the excenter with all high pressure elements as a set.

Fig. 9-2: Excenter bearing

51


9.3 Measuring the camshaft

Perform a visual inspection of the shaft for damage to the threads and for grooves caused by the shaft sealing ring.

Using an outside micrometer, measure the camshaft at the mating surface to the flange bearing:



ATTENTIONIf the tolerance is exceeded, the camshaft must be re-placed.

Using an outside micrometer, measure the camshaft at the mating surface to the housing bearing:




Fig. 9-3: Camshaft (front)

Fig. 9-4: Camshaft (rear)



Using an outside micrometer, measure the cam of the camshaft:




Fig. 9-5: Camshaft Cam

Fig. 9-6: Measuring the control plate

9.4 Measuring the control plate

Check shaft bearing in control plate using inner precision instrument and replace control plate, if necessary.


53


Fig. 9-7: High pressure pump cover, control plate and Gerotor

9.5 Checking the Gerotor, high pressure pump cover and control plate

Perform a visual inspection for mechanical damage and grooves on the inner and outer rotor, high pressure pump cover and control plate.

9.6 Testing the VCV

Test the electrical resistance of the VCV coil using an ohmmeter:

Nominal value: 2.4 Ohm +/– 0.25 Ohm

Fig. 9-8: Testing the VCV

55


10 Assembling the high pressure pump (Start/Stop)


10.1 Installing the shaft sealing ring

Have the following parts ready:

• New shaft sealing ring• Pressure piece VW/DV6 shaft sealing ring• New shaft sealing ring• Gasket kit shaft• Pressure pad shaft sealing ring VW/DV6C

1. Carefully place new shaft sealing ring and pressure pad on the seat in the high pressure pump housing and align horizontally.

2. Using a suitable tool (e.g. lever press), press the shaft sealing ring until the pressure pad comes into contact with the high pressure pump housing. ATTENTION Shaft sealing ring is not seated flush with the high pressure pump housing but recessed by 0.5 +/- 0.3 mm. Special tool: Use pressure pad VW shaft sealing ring!

Fig. 10-1: High pressure pump housing with shaft sealing ring

Fig. 10-2: High pressure pump housing with pressure pad shaft sealing ring VW/DV6C



3. Insert the new sealing ring in the interior of the high pressure pump.




10.2 Installing the camshaft

Observe the following when inserting the camshaft: • With the OE number 03L 130 755 S, use the

camshaft for VW AWP2 India (article number: A2C5341142480).

• Do not damage the sealing lip of the shaft sealing ring.

• Do not wet the shaft sealing ring and camshaft with lubricants.

• The running-in procedure between sealing lip and camshaft occurs dry.

1. Insert the expanding side of the fit up aid/VW camshaft at right angle to the shaft sealing ring.

Fig. 10-3: High pressure pump housing with inner shaft sealing ring

Fig. 10-4: Fit up aid for camshaft expanding side faces the shaft sealing ring

57


Fig. 10-6: Drive pin of the camshaft in fit up aid

Fig. 10-5: Fit up aid for camshaft shaft receiving side faces the shaft sealing ring

2. After waiting 5 seconds, quickly turn the fit up aid by 180° and carefully insert with shaft receiving side in the shaft sealing ring.

3. Insert camshaft inside high pressure pump housing in shaft receiving side of the fit up aid. Make sure that the drive pin is correctly seated!



Fig. 10-7: High pressure pump housing with inserted camshaft

4. Push the pump shaft with the excenter attached in one movement sequence against the fit up aid until the shaft touches the high-pressure pump housing.

59


10.3 Installing the control plate and ITP (Gerotor)

1. Provide control plate with new sealing rings (3 pc.) and place on.

Fig. 10-8: High pressure pump housing with control plate

Fig. 10-9: Control plate



Fig. 10-10: Control plate with inner and outer rotor

Fig. 10-11: Control plate with inner and outer rotor

2. Install the Gerotor so that the marks from inner and outer rotor face down to the control plate.

61


10.4 Installing the high pressure pump cover


• Inspected or new high pressure pump cover • Mounting screws • Torque wrench

1. Place high pressure pump cover onto the high pressure pump housing.

2. Insert mounting screws of the high pressure pump cover (4 pc., Torx 30) and tighten slightly.

3. Tighten the mounting screws of the high pressure pump cover crosswise slightly and then tighten to the specified torque.

Tightening torque:Screw high pressure pump cover to high pressure pump housing: 12 Nm




10.5 Installing high pressure elements


• Gasket kit high pressure element• Torque wrench

ATTENTIONNever install high pressure elements without gaskets.


Tilt the high pressure pump in the mounting device towards the front.

To insert the high pressure elements more easily, turn the camshaft until the flat side of the excenter is standing in the direction of the opening of the high pressure element (bottom dead centre).

1. Insert sealing ring low pressure side (1)

Fig. 10-13: Gasket kit high pressure element

Fig. 10-14: Sealing ring (low pressure)

1

4

2 3

1

63


Fig. 10-16: High pressure element

Fig. 10-15a: Support ring (2) and sealing ring (3) (high pressure)

Fig. 10-15b: High pressure element with base gasket

2. Insert support ring (2) and sealing ring (3) high pressure side.

3. Place base gasket (4) onto seat surface of the high pressure element.

4. Carefully place on high pressure element (after turning the shaft to bottom dead centre); screw in all 4 screws with approx. 1 to 2 turns, then with ONE movement, press down high pressure element using suitable clamping device.

5. Then tighten the four screws crosswise under pretension.

6. Repeat working steps 1–5 for second high pressure element.

To install the other two high pressure elements, swivel the mounting device on the longitudinal axis.

Tightening torque:Screw high pressure element at high pressure pump: 25 Nm

1

2

3

4



10.6 Installing the high pressure connection


• Torque wrench• High pressure connection repair kit

ATTENTIONNever install high pressure connection without the pinhole aperture. Without the aperture, the high pressure pump will malfunction. Leaks can occur if two apertures are used (possibly old and new).


1. Insert the aperture in the high pressure connection.

2. Insert high pressure connection and tighten slightly.

3. Tighten high pressure connection to the specified torque.

4. Attach protective cap for the high pressure connection.

Tightening torque: High pressure connection to high pressure pump: 30 +/– 2 Nm



65


Fig. 10-19: VCV with mounted filter

10.7 Installing the VCV


• Filter• VCV• Torque wrench• Hexagon insert 3/8“, extra long (4 mm)

1. Grease the sealing ring of the filter slightly (all-purpose grease).

2. Place filter onto VCV.

3. Join VCV with attached filter to high pressure pump flange and tighten.

Tightening torque:VCV to high pressure pump: 6 Nm

ATTENTIONIn certain versions of the CR high pressure pump no filter is installed at the factory. The installation of the VCV is done without filter. A retrofitting of the filter is not technically possible!

Fig. 10-20: Tightening the VCV



10.8 Attaching the DRS type plate


• DRS type plate

1. Clean surface.

2. Attach the DRS type plate.

3. Place a visible mark in the immediate vicinity of the original pump type plate using a centre punch.

The original pump type plate must remain visible on the pump.

Fig. 10-21: Position of the type plate

67


11 Testing on approved pump test stand

Observe chapter 1 “Safety information” for all work on the test stand . Make sure that you have read and under-stood all safety information .

11.1 Checking the high pressure pump

Check of the functioning and leak tightness of the repaired high pressure pump on the test stand.

Testing is done with a test plan approved by Continental. Follow the instructions in the test plan .

ATTENTIONThe high pressure pump may only be installed in the vehicle again after passing the test on the pump test stand. An incorrect repair can lead to malfunction of the engine as well as to environmental damage caused by leaking diesel fuel.

Fig. 11-1a: Example pump test stand Hartridge

Fig. 11-1b: Example pump test stand Bosch



11.2 Placing on the design cover

To prevent test oil from leaking, all connections must be sealed after testing the high pressure pump.

Attach the design cover to the high pressure element again.

Fig. 11-2: High pressure pump with sealed connections

69


Figure Designation Order number

Basic mounting holder for CR pumps

2910000419200

Basic shaft holder CR pump 2910000417700

Pump holderVW / DV6C

2910000417600

12 Special tools




Tool set VDO CR pumps – A

Contents: • Pressure pad shaft sealing ring• Camshaft fit up aid• Special pliers for filter removal

2910000803300

Torque wrench (Purchase at specialist shop)

Outside micrometerPrecision: 0.001 mm

(Purchase at specialist shop)

71



Inner precision instrument (Purchase at specialist shop)

Dial indicator gaugePrecision: 0.001 mm


Internal extractor for shaft sealing ring





Multimeter (Purchase at specialist shop)

73



Protective plugs VW CR pumps

2910000435200

Gasket kit for high pressure elements VW CR pump without ITP

Gasket kit for high pressure elements VW CR pump Start/Stop

A2C2000076980

A2C5333369180

Gasket kit cover VW CR pump Start/Stop

A2C5332518180

13 Repair parts




Gasket kit cover VW CR pump without ITP

A2C5321418280

Filter for VCVVW CR pumps

A2C8494170080

VCVVW CR pumps

A2C5329064080

75



Shaft VW CR Pump Start/Stop

ITP AWP2 (India)

A2C5321418980

A2C5341142480

Shaft VW CR pump without ITP

A2C5336672380

High pressure connection VW CR pumps

A2C5327848280




ITP VW CR Pump Start/Stop

A2C5321418380

High pressure elementsVW CR pumps

A2C5335028280

Control plate VW CR Pump Start/Stop

A2C5335028280

77



cap VW CR Pump Start/Stop with VCV

A2C8494150080

cap VW CR Pump without ITP with VCV

A2C8527240080

Shaft sealing ringVW CR pumps

A2C5328614180

79


14 Glossary

Common Rail (CR): The common-rail injection, which is also referred to as accumulator fuel injection, is an injection system for internal combustion engines in which a high pressure pump brings the fuel to a high pressure level.

Diesel Common Rail Pump (DCRP): The diesel common rail pump is used to transport the fuel via the distributor rail and the injectors into the combustion chamber of the engine at a system-specific fuel pressure.

Internal Transfer Pump (ITP): The internal transfer pump is an integrated, mechanical device for transporting the fuel into the high pressure chambers of the diesel common rail pump.

Volume Control Valve (VCV): The volume control valve controls the amount of fuel supplied to the high pressure cham-bers of the pump.

Pressure Control Valve (PCV): The pressure control valve controls the pres-sure of the fuel generated in the distributor rail by the high-pressure pump.

diesel common rail pump - auto...

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