Audi Workshop Service and Repair Manuals > A3 Mk2 > Power unit | Motronic Direct Injection and Ignition System (4-Cyl.) | Mixture preparation system, electronic inj.,Gas | Servicing injection system | Removing and installing high-pressure pump (engine code letters BAG)

Removing and installing high-pressure pump (engine code letters BAG)

Special tools and workshop equipment required

t	Torque wrench (4...20 Nm) with ratchet -V.A.G 1410-

Removing

Note

t	The high-pressure fuel pump should only be removed and installed when the engine is cold.

t	When installing the high-pressure fuel pump, it is essential to ensure that no dirt enters the fuel system.

t	The high-pressure pump must not be dismantled.

WARNING

Fuel supply line is pressurised. Before loosening fuel connections always release fuel pressure prior to carrying out any work → Chapter.

–	Remove engine cover panel → Chapter.

–	Remove connecting pipe -6-.

–	Loosen union nut -3-.

–	Unscrew banjo bolts -1-, -2- and -5-.

Note

Use a cloth to catch escaping fuel.

–	Detach connector -1-.

–	Detach fuel line connections -3- and -4- from high-pressure pump -5-.

–	Remove securing bolts -2-.

–	Detach high-pressure pump -5- from camshaft housing.

Installing

Installation is carried out in the reverse order; note the following:

Note

t	Lubricate sleeve of high-pressure pump with clean engine oil.

t	Always renew O-ring for high-pressure pump.

–	Fit high-pressure pump -5- with new, oiled O-ring in camshaft housing.

–	Tighten securing bolts -2- on high-pressure pump -5- to 10 Nm.

–	Refit connector -1-.

–	Fit fuel lines -3- and -4- onto high-pressure pump.

–	Tighten banjo bolts -1- and -2- to 15 Nm

–	Install high pressure pipe -4- as follows:

1 -	Screw in banjo bolt -5- 2 turns by hand.

2 -	Screw in union nut -3- onto stop by hand.

3 -	Screw in banjo bolt -5- onto stop by hand.

4 -	Tighten banjo bolt -5- to 15 Nm

5 -	Tighten union nut -3- to 15 Nm.

–	Install connecting pipe -6-.

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