Audi Workshop Service and Repair Manuals

Removing and installing high-pressure pump - vehicles from 09.2005 onwards

Special tools and workshop equipment required

t	Counterhold tool -3036-

t	Torque wrench -V.A.G 1331-

t	Ratchet -V.A.G 1331/1-

t	Puller -T10320-

t	Socket -T40055- (17 mm)

t	Puller -T40064-

Removing   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system. –  Remove engine cover panel → Chapter.

–  Unscrew union nuts -1 ... 4- and detach high-pressure pipes. –  Remove intake manifold (top section) → Chapter. –  Remove toothed belt for high-pressure pump → Chapter.

–  Loosen central nut -1- for high-pressure pump shaft using counterhold tool -3036-. –  Remove damper weight.

–  Use puller -T40064- to pull off belt sprocket for high-pressure pump.

–  Disconnect fuel supply line -2- and fuel return line -1- from high-pressure pump and move lines clear to the side.

–  Remove bolts -1 ... 4-.

–  Remove bolts -1- and -3-. –  Unplug electrical connector -2-. –  Carefully pull toothed belt cover in direction of -arrow- and lift out high-pressure pump. Installing Installation is carried out in the reverse order; note the following:   Caution A new high-pressure pump must first be filled with fuel before the engine is started. The high-pressure pump must not be allowed to run while still empty. Bleeding fuel system → Chapter   Note t  Renew seals and gaskets. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Hand-tighten union nuts on high-pressure pipes. Make sure that connections are not under tension. –  To tighten unions of high-pressure pipes at rail elements, use torque wrench -V.A.G 1331- with tool insert, AF 19 -V.A.G 1331/5-.

–  To tighten union of high-pressure pipe at high-pressure pump, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket -T40055-, 17 mm. –  Install toothed belt for high-pressure pump → Chapter. –  Install intake manifold (top section) → Chapter. –  Bleed high-pressure pump → Chapter. –  Bleed fuel system and check for leaks → Chapter. Tightening torques

Component		Nm
Front bracket to high-pressure pump		23
High-pressure pump with front bracket to bracket (rear)		23
High-pressure pump with front bracket to engine	M6	9
	M8	23
Fuel supply and return lines to high-pressure pump		25
Toothed belt cover (rear) to engine		9
Damper weight to high-pressure pump		70
Toothed belt drive sprocket to camshaft		75
High-pressure pipes		25