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High Pressure Fuel Pump Replacement
 
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Pelican Technical Article:

High Pressure Fuel Pump Replacement

Steve Vernon

Time:

1hour

Tab:

$1,300

Talent:

***

Tools:

14mm flared nut wrench, 17mm, 10mm wrench

Applicable Models:

Cayenne GTS (2008-10)
Cayenne S (2008-10)
Cayenne Turbo (2008-10)
Cayenne Turbo S (2008-10)
Panamera 4S (2010-13)
Panamera GTS (2013-14)
Panamera S (2010-13)
Panamera Turbo (2010-14)
Panamera Turbo S (2012-14)
Pamamera Turbo Executive (2014-14)
Panamera Turbo S Executive (2014-14)

Hot Tip:

Be prepared to catch spilling fuel

Performance Gain:

Proper engine functionality

Complementary Modification:

Replace injectors

The high-pressure fuel pump in the direct injection motors in the Porsche Cayenne is in addition to the regular fuel pump. This pump, which is mounted to and driven by the left side cam, generates between 580 psi or 40 bar and 1740 psi or 120 bar depending whether the motor is at idle or wide open throttle

The left side cam drives the pump. Once the engine is off it dissipates the pressure quickly. That being said, even when the engine is cold, there will be some residual fuel in the pump. Be prepared to catch it and dispose of it correctly.

As always, when working around fuel take all necessary precautions: wear gloves and eye protection, work in a well ventilated area and do not work around any open flame or hot lights. Let the motor cool down before beginning work.

While I have heard of people who claim to have changed the pump out while the intake manifold is still on the motor, I recommend removing the manifold. There is very little space to work with it removed. I can't imagine how you can get access with it in place.

You are going to remove the intake manifold to give you room to access the pump.
Figure 1

You are going to remove the intake manifold to give you room to access the pump. Please see our article on intake manifold removal for additional assistance.

The high-pressure fuel pump sits on the rear of the left head and is driven by the camshaft (red arrow).
Figure 2

The high-pressure fuel pump sits on the rear of the left head and is driven by the camshaft (red arrow). There is a stainless steel line out from it to the fuel rail (yellow arrow).

There is a sturdy metal protective crash plate behind the pump in front of the firewall.
Figure 3

There is a sturdy metal protective crash plate behind the pump in front of the firewall. Use a 10mm wrench and remove the three bolts (red arrow).

With the bolts removed remove the plate (red arrow).
Figure 4

With the bolts removed remove the plate (red arrow).

Using a 17mm wrench disconnect the fuel input line (red arrow) from where it enters the pump (yellow arrow).
Figure 5

Using a 17mm wrench disconnect the fuel input line (red arrow) from where it enters the pump (yellow arrow). A small amount of fuel will spill out so be prepared to catch it and dispose of it correctly.

Use a 14mm flared nut wrench and disconnect the fuel out line from the pump (red arrow).
Figure 6

Use a 14mm flared nut wrench and disconnect the fuel out line from the pump (red arrow). Once again, a small amount of fuel will spill out so be prepared to catch it and dispose of it correctly.

There are three studs that hold the protection plate in place.
Figure 7

There are three studs that hold the protection plate in place. These also secure the pump to the head. Use a 10mm wrench and remove the studs on the right side (red arrow).

This photo illustrates one of the studs that hold the pump to the head and the protective plate on behind the pump (red arrow).
Figure 8

This photo illustrates one of the studs that hold the pump to the head and the protective plate on behind the pump (red arrow).

Use a 10mm wrench and remove the additional left side bolt that holds the pump to the head (red arrow).
Figure 9

Use a 10mm wrench and remove the additional left side bolt that holds the pump to the head (red arrow).

With the bolts removed you can remove the pump from the cam.
Figure 10

With the bolts removed you can remove the pump from the cam. Note the position of the pump drive adaptor that has two metal studs that come out of it (red arrows). These need to line up with where they engage the cam when installing the new pump. Try not to rotate them or let them fall off the end of the shaft.

It is much easier to separate the electrical connection (red arrow) for the pump once it is off the camshaft and you are holding the adaptor plate securely in your hand.
Figure 11

It is much easier to separate the electrical connection (red arrow) for the pump once it is off the camshaft and you are holding the adaptor plate securely in your hand.

Transfer the adaptor plate from the old pump to the new one (red arrow) and rotate the pump until the adaptor plate is in the same direction as the pump you just removed.
Figure 12

Transfer the adaptor plate from the old pump to the new one (red arrow) and rotate the pump until the adaptor plate is in the same direction as the pump you just removed. This will help line it up with the camshaft. If for some reason you are putting the old pump back on always replace the O-ring (yellow arrow). Installation is the reverse of removal.

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Comments and Suggestions:
Faeq Abdul Hameed Janahi Comments: My car has a problem with the high pressure pump I have checked with the dealer and it's very expensive $ 1200 I cannot afford it this price without labour charge can you please tell me what is the best price for it. Thanks in advance. FAEQ JANAHI TEL: 0097334017717
October 3, 2016
  Followup from the Pelican Staff: Give our parts specialists a call at 1-310-626-8765 - Nick at Pelican Parts  
reese5997 Comments: Hello, the diaphragm to my HPFP started leaking oil on my 09 CS; it is a slow leak. Is there a vendor who sells the diaphragm separately?
January 15, 2016
  Followup from the Pelican Staff: Not 100% sure. Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 

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