Audi Workshop Service and Repair Manuals

Removing and installing high-pressure pump Special tools and workshop equipment required

t  Counterhold tool -3036-

t  Puller -T40064-   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. Removing –  Remove top section of intake manifold → Chapter. –  Remove toothed belt for high-pressure pump → Chapter.

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

–  Remove toothed belt sprocket for high-pressure pump using puller -T40064-.

–  Unscrew bolts -arrows- and remove connecting pipe -1- for exhaust gas recirculation.

–  Unscrew bolt -arrow-, pull off oil supply line for turbocharger and move to one side.

–  Remove union nuts -2- and -4-, move high-pressure pipe clear and remove.   Note Disregard -items 1 and 3-.

–  Unscrew banjo bolt -2- for fuel supply hose and banjo bolt -1- for fuel return hose and move fuel hoses to one side.   Caution Observe rules for cleanliness when working on the injection system → Chapter.

–  Remove bolts -1, 2, 4- and -arrows-. –  Unplug electrical connector -3-. –  Carefully pull toothed belt cover forward and lift out high-pressure pump. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals and gaskets. t  Fuel return line must not be kinked, damaged or clogged l  Tightening torques → Chapter

–  Secure oil supply line for turbocharger -arrow- → Rep. gr.21. –  Install toothed belt for high-pressure pump → Chapter. –  Install high-pressure pipes → Chapter. –  Install top section of intake manifold → Chapter. –  Bleed fuel system and check for leaks → Chapter.