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High Pressure Fuel Sensor Replacement
 
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Pelican Technical Article:

High Pressure Fuel Sensor Replacement

Steve Vernon

Time:

45 minutes45 mins

Tab:

$40

Talent:

*

Tools:

23mm or large adjustable wrench

Applicable Models:

VW GTI (2006-09)

Parts Required:

High pressure fuel sensor

Hot Tip:

Work on a cold engine

Performance Gain:

Car runs like normal again

Complementary Modification:

Replace fuel injectors

The Volkswagen GTI MkV has two separate fuel pumps; one in the tank and a high pressure pump mounted on the cylinder head and driven by the camshaft. Fuel pressure is critical on most engines but even more so on the direct injection motors. If you are getting an error code that you have low fuel pressure to the high pressure pump changing your sensor is the first step in trouble shooting. There is also a sensor on the high pressure pump. This sensor is getting more difficult to find but this article will show you how to replace it.

Your going to be working on the fuel system so be prepared: Work in a well ventilated area. Keep a fire extinguisher near you at all times and know how to use it correctly. No sparks or open flame around and if you smoke now would be a really good time to quit: at least for the half hour it might take you to perform this job.

Just as with the fuel filter, injectors, or any other component of the fuel system, it's best to relieve the fuel system of any pressure before you go opening it up. The engine should be cold while doing this so open the gas cap while the motor is cooling down and help relieve the vacuum in the system. Also, be sure to use some protective gloves and goggles whenever you're working with fuel.

If you do not have an after market air induction system you will need to remove the engine cover.
Figure 1

If you do not have an after market air induction system you will need to remove the engine cover. Please see our article on engine cover removal for additional assistance.

You are going to want to run the fuel out of the system.
Figure 2

You are going to want to run the fuel out of the system. Begin by opening the access panel on the left side of the dash by using a trim removal tool and gently prying the panel out from the dash (red arrow).

Use the fuse removal tool on the back of the panel and remove the fuse for the fuel pump (red arrow).
Figure 3

Use the fuse removal tool on the back of the panel and remove the fuse for the fuel pump (red arrow). Make sure to check with your owners manual to locate the proper fuse. With the fuse removed try to start the engine; if it does start it will die quickly from fuel starvation. Usually a couple turns of the key will do it.

There is a Schrader valve located on the pump housing (red arrow).
Figure 4

There is a Schrader valve located on the pump housing (red arrow). You can unscrew the cap and use the valve to relieve any residual pressure. Have a rag or cloth handy to catch whatever remaining fuel that will come out.

Separate the wiring connection from the pump (red arrow).
Figure 5

Separate the wiring connection from the pump (red arrow).

Use a large adjustable wrench and remove the sensor from the pump.
Figure 6

Use a large adjustable wrench and remove the sensor from the pump. You must always replace the O-ring (red arrow) even if reinstalling the sensor. Installation is the reverse of removal.

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Comments and Suggestions:
Jon Comments: How much for this sensor? I need to replace mine because its broken. And can it be send to the netherland
December 5, 2016
DopyGolfer Comments: Where can i find this sensor?
Are you guys selling them?
Im in australia.
September 11, 2015
  Followup from the Pelican Staff: I'm not 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
 
Red Comments: Do you know the part number for "High Pressure Fuel Sensor " or a link to where I can buy one?
April 19, 2015
  Followup from the Pelican Staff: We can get it for you. 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
 
Shaun Comments: Thanks for your response Nick. I will check with my mechanic & let you know. I take this opportunity to wish you & your family a safe & enjoyable Christmas and all the best for 2015.
December 25, 2014
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
DR Comments: Around June this year I started to notice that my VW Golf Mark V had a problem particularly on a cold start, namely there were flat spots when you acclerate and only after the car warms up does it clear. On the advice of my mechanic we fitted 4 x new injector nozzles, which did not clear the problem but helped a little. My mechanic then said that the High Pressure Pump needed to be replaced so I purchased a new pump from a VW Dealer; when he fitted it he said that the idling was erratic and therefor fitted back the old pump. He claims that the pump is faulty but that I also need to order a new Throttle Body. I have since been driving the car as is- start in the morning and let the engine warm-up before moving; also do not accelerate too much. It has been running ok for the last 10 days but with the flat spots still evident. This afternoon after returning back from the health club I was stuck in traffic crawling up a hill when the car started to flat spot and jerk. I barely made it back to the office. Can you please advise what I should do?
December 22, 2014
  Followup from the Pelican Staff: When the new pump was installed, can you confirm it was properly timed? It sounds like you are getting a lot of back and forth. I would start from the beginning, the basics and get some direction. If needed, get a second opinion from a different mechanic. - Nick at Pelican Parts  

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