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High-pressure pump screw sheared off, need help

 
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Post13-06-2019, 12:59    Subject: High-pressure pump screw sheared off, need help Quote

Hello.
I wanted to replace the turbocharger on my Opel 1.7 CDTI (17DTR), but unfortunately, one of the screws broke off in the process.
The pump is driven by the timing belt in this engine and is located in a very unfavorable position between the engine block and the splash guard.
Does anyone have a good suggestion for me? Should I try to drill it out, or should I just remove it altogether?
How would you approach that?

Thank you very much.



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Golf III TDI AHU 402Tkm
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Translated on 07-07-2026, 4:31.
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Post13-06-2019, 19:04    Subject: High-pressure pump screw sheared off, need help Quote

Hello,

In that spot, I wouldn't expect to find any rust, so a stripped screw should be relatively easy to remove.

I would try to drill a hole in the center of the screw and then use an extractor.
If you have a left-hand drill bit that fits, use that one. icon_biggrin.gif

Best regards, Rainer.


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bindpe
Blaumann
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Location: ingolstadt

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Post13-06-2019, 20:25    Subject: High-pressure pump screw sheared off, need help Quote

No, there's no rust there, I have no idea why the screw broke off.
I took another look at it carefully, and there's no way to drill in that space while it's installed. I guess I'll have to remove the pump.
Have you ever disassembled a common rail pump before? Is there anything I should be aware of?
Golf III TDI AHU 402Tkm
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Translated on 07-07-2026, 4:33.
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Post13-06-2019, 21:17    Subject: High-pressure pump screw sheared off, need help Quote

Please pay close attention to cleanliness! Make sure to thoroughly bleed the system before attempting to start it. icon_idea.gif


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Post15-06-2019, 7:07    Subject: High-pressure pump screw sheared off, need help Quote

Thank you for the information.

I will pay attention to cleanliness.
"How can I best bleed the system? Unfortunately, the car doesn't have a pre-lift pump, and the manufacturer's repair manual doesn't have any information about it either."

Thank you.
Golf III TDI AHU 402Tkm
Spritmonitor.de


Translated on 07-07-2026, 4:34.
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