Audi Workshop Service and Repair Manuals

Notes:

• ◆ The high-pressure fuel pump should only be removed and installed when the engine is cold.
• ◆ When assembling the high-pressure fuel pump, it is essential to ensure that no dirt enters the fuel system.
• ◆ Use a rag to catch any discharged fuel.

Removing high-pressure fuel pump after reducing fuel pressure

• ‒ → Disconnect fuel supply line -2- from high-pressure fuel pump.
• ‒ Disconnect high-pressure fuel line -1- from high-pressure fuel pump and fuel rail pipe.
• ‒ Unscrew the three bolts -arrows-. If necessary, undo cable ties on wiring harness.
• ‒ Rotate high-pressure fuel pump anticlockwise until the high-pressure line -2- can be pulled out of the high-pressure fuel pump.
• ‒ Pull high-pressure fuel pump out of camshaft housing.

Installing high-pressure fuel pump

Notes:

• ◆ The O-ring of the high-pressure fuel pump must always be replaced.
• ◆ The high-pressure fuel line must always be replaced.

• ‒ When installing high-pressure fuel pump in camshaft housing, pay attention to pin which must be inserted into high-pressure fuel pump.
• ‒ Hand-tighten new high-pressure line on fuel rail pipe.

• ‒ Rotate high-pressure fuel pump anticlockwise slightly and then clockwise again while carefully inserting new high-pressure line into high-pressure fuel pump.
• ‒ → Screw union bolt -1- approx. 2 turns onto high-pressure fuel pump.
• ‒ Securely bolt down high-pressure fuel pump using the three bolts -arrows-.

• Torque: 10 Nm

• ‒ Securely tighten high-pressure line.

• Torque: 15 Nm

• ‒ → Reconnect fuel supply line -2- to high-pressure fuel pump. Make sure that hose clamp is securely fitted.
• ‒ With engine idling, check high-pressure fuel pump and fuel lines for leaks.