diesel common rail pump - auto...
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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.
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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
© Continental Trading GmbH4
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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.
© Continental Trading GmbH6
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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.
© Continental Trading GmbH8
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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.
© Continental Trading GmbH10
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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.
© Continental Trading GmbH12
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
5 Dismantling the high pressure pump (without ITP)
Exploded view of VW CR Pump without ITP
© Continental Trading GmbH14
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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!
© Continental Trading GmbH16
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH18
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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.
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH20
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH22
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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.
© Continental Trading GmbH24
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
6.2 Measuring the excenter
Using an inner precision instrument, measure the bearing of the excenter:
Nominal values: Max: 31.043 mm/Min: 31.013 mm
ATTENTIONIf the tolerance is exceeded, replace the excenter with all high pressure elements as a set.
Fig. 6-2: Excenter bearing
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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:
Nominal values: Max: 24.980 mm/Min: 24.967 mm
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:
Nominal values: Max: 21.980 mm/Min: 21.967 mm
Perform measurement at two points offset by 90°.
ATTENTIONIf the tolerance is exceeded, the camshaft must be replaced.
Fig. 6-3: Camshaft (front)
Fig. 6-4: Camshaft (rear)
© Continental Trading GmbH26
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
Using an outside micrometer, measure the cam of the camshaft:
Nominal values: Max: 30.975 mm/Min: 30.959 mm
Perform measurement at two points offset by 90°.
ATTENTIONIf the tolerance is exceeded, the camshaft must be replaced.
6.4 Measuring the high pressure pump cover
Measure the high pressure pump cover. Using an inner precision instrument, measure the bearing.
Nominal values: Max: 22.025 mm/Min: 21.995 mm
Fig. 6-5: Camshaft Cam
Fig. 6-6: Measuring the high pressure pump cover
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH28
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
7 Assembling the high pressure pump (without ITP)
All subsequently described activities refer to work on the removed high pressure pump .
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
© Continental Trading GmbH30
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
slip, e.g. to a workbench. • Wear safety shoes.
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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!
© Continental Trading GmbH32
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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.
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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. 7-9: High pressure pump cover
Fig. 7-8: High pressure pump housing with high pressure pump cover
6
5
© Continental Trading GmbH34
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
7.4 Installing high pressure elements
Have the following ready for the installation:
• 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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH36
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
7.5 Installing the high pressure connection
Have the following ready for the installation:
• 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).
ATTENTIONRisk of fire due to external leakage
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
Fig. 7-14: Pinhole aperture in the high pressure connection
Fig. 7-15: High pressure pump connection
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
Fig. 7-16: VCV with mounted filter
7.6 Installing the VCV
Have the following ready for the installation:
• 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
© Continental Trading GmbH38
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
7.7 Attaching the DRS type plate
Have the following ready for the installation:
• 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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
8 Dismantling the high pressure pump (Start/Stop)
Exploded view of VW CR Pump Start/Stop
© Continental Trading GmbH40
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
All subsequently described activities refer to work on the removed high pressure pump .
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.
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 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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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.
© Continental Trading GmbH42
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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.
Fig. 8-5: High pressure pump connection
Fig. 8-6: Pinhole aperture in the high pressure connection
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH44
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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.
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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.
Fig. 8-10: High pressure pump cover
To better facilitate removing the high pressure pump cover, you can tilt the mounting device.
© Continental Trading GmbH46
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH48
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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:
Nominal values: Max: 25.047 mm/Min: 25.017 mm
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.
© Continental Trading GmbH50
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
9.2 Measuring the excenter
Using an inner precision instrument, measure the bearing of the excenter:
Nominal values: Max: 31.043 mm/Min: 31.013 mm
ATTENTIONIf the tolerance is exceeded, replace the excenter with all high pressure elements as a set.
Fig. 9-2: Excenter bearing
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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:
Nominal values: Max: 24.980 mm/Min: 24.967 mm
Perform measurement at two points offset by 90°.
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:
Nominal values: Max: 21.980 mm/Min: 21.967 mm
Perform measurement at two points offset by 90°.
ATTENTIONIf the tolerance is exceeded, the camshaft must be replaced.
Fig. 9-3: Camshaft (front)
Fig. 9-4: Camshaft (rear)
© Continental Trading GmbH52
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
Using an outside micrometer, measure the cam of the camshaft:
Nominal values: Max: 30.975 mm/Min: 30.959 mm
Perform measurement at two points offset by 90°.
ATTENTIONIf the tolerance is exceeded, the camshaft must be replaced.
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.
Nominal values: Max: 22.025 mm/Min: 21.995 mm
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH54
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
10 Assembling the high pressure pump (Start/Stop)
All subsequently described activities refer to work on the removed high pressure pump .
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
© Continental Trading GmbH56
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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 can not
slip, e.g. to a workbench. • Wear safety shoes.
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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!
© Continental Trading GmbH58
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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.
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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.
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
10.4 Installing the high pressure pump cover
Have the following ready for the installation:
• 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
Fig. 10-12: High pressure pump cover
© Continental Trading GmbH62
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
10.5 Installing high pressure elements
Have the following ready for the installation:
• 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. 10-13: Gasket kit high pressure element
Fig. 10-14: Sealing ring (low pressure)
1
4
2 3
1
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH64
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
10.6 Installing the high pressure connection
Have the following ready for the installation:
• 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).
ATTENTIONRisk of fire due to external leakage
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
Fig. 10-17: Pinhole aperture in the high pressure connection
Fig. 10-18: High pressure pump connection
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
Fig. 10-19: VCV with mounted filter
10.7 Installing the VCV
Have the following ready for the installation:
• 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
© Continental Trading GmbH66
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
10.8 Attaching the DRS type plate
Have the following ready for the installation:
• 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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
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
© Continental Trading GmbH68
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
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
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
Figure Designation Order number
Basic mounting holder for CR pumps
2910000419200
Basic shaft holder CR pump 2910000417700
Pump holderVW / DV6C
2910000417600
12 Special tools
© Continental Trading GmbH70
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
Figure Designation Order number
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)
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
Figure Designation Order number
Inner precision instrument (Purchase at specialist shop)
Dial indicator gaugePrecision: 0.001 mm
(Purchase at specialist shop)
Internal extractor for shaft sealing ring
(Purchase at specialist shop)
© Continental Trading GmbH72
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
Figure Designation Order number
Multimeter (Purchase at specialist shop)
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
Figure Designation Order number
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
© Continental Trading GmbH74
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
Figure Designation Order number
Gasket kit cover VW CR pump without ITP
A2C5321418280
Filter for VCVVW CR pumps
A2C8494170080
VCVVW CR pumps
A2C5329064080
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
Figure Designation Order number
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
© Continental Trading GmbH76
VW CR Pump Start/Stop · VW CR Pump without ITP Diesel Common Rail Pump
Figure Designation Order number
ITP VW CR Pump Start/Stop
A2C5321418380
High pressure elementsVW CR pumps
A2C5335028280
Control plate VW CR Pump Start/Stop
A2C5335028280
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VW CR Pump Start/Stop · VW CR Pump without ITPDiesel Common Rail Pump
Figure Designation Order number
cap VW CR Pump Start/Stop with VCV
A2C8494150080
cap VW CR Pump without ITP with VCV
A2C8527240080
Shaft sealing ringVW CR pumps
A2C5328614180
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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.