Audi Workshop Service and Repair Manuals

Removing and installing injection pump Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Ring spanner -3035- t  Locking pin -3242- t  Diesel injection pump locking pin -3359-   Note t  For security reasons, in all vehicles as from the 2002 model year the injection pump is integrated in the immobiliser system. t  When an injection pump has been renewed, it must be re-adapted to the immobiliser. t  The adaption of the injection pump is described in the Guided Fault Finding or Guided Functions. Removing –  Remove engine cover panel → Chapter.

–  Remove viscous fan. –  Remove toothed belt covers (front left and right).

–  Remove front section of intake manifold → Chapter. –  Open oil filler cap.

–  Turn engine until the marking “- OT -” (TDC) is visible on camshaft.   Note Turn over the engine at the central bolt on the crankshaft. –  Unscrew plug for TDC marking from crankcase. The crankshaft is provided with a TDC drilling, which can be felt directly below the plug.

–  Screw locking pin -3242- into threaded hole where plug has been removed, and tighten locking pin -3242-.

–  Remove vibration damper on injection pump sprocket (bolts -1-).   Note Do NOT loosen nut - 2 - for injection pump sprocket. Otherwise this would alter the basic setting of the injection pump. The setting cannot be re-adjusted with workshop equipment. –  Mark direction of rotation of toothed belt. The belt can break if it rotates in the opposite direction when refitted.

–  Slacken toothed belt tensioner and take off toothed belt. –  Unplug electrical connector from injection pump. –  Disconnect fuel supply and return pipes from injection pump. –  Cover open connections with a clean cloth. –  Disconnect injector pipes from injectors using open ring spanner -3035-.

–  Unscrew injection pump mountings. –  Lift out injection pump together with injector pipes. –  Mark injector pipes according to cylinders. –  Disconnect injector pipes from injection pump using ring spanner -3035-. Installing injection pump –  Mount injection pump on engine and bolt it in place. –  Bolts on crankcase: 20 Nm

–  Bolts on toothed belt cover: 10 Nm –  After tightening injection pump mountings, fit injector pipes one at a time, working from bottom to top and secure using torque wrench -V.A.G 1331- and 17 mm open ring spanner attachment (commercially available). Tightening torque for injection pipes: 30 Nm   Note t  When tightening the connections, make sure the injector pipes are not twisted or under tension. t  Incorrect assembly will distort the taper sets of the pipe unions. t  Secure the retaining clips on the injector pipes in their original positions and without tension.

–  Lock injection pump sprocket with diesel injection pump locking pin -3359-.

–  Slacken camshaft sprocket -1- and align centrally in longitudinal holes. –  Fit toothed belt. Pay attention to the direction of rotation as marked upon removal. –  Tension toothed belt. To do so, turn Allen key anti-clockwise until markings -1- are in line, then tighten securing nut.

–  Tightening torque: 36 Nm –  Tighten bolts at camshaft sprocket. –  Tightening torque: 20 Nm

–  Remove diesel injection pump locking pin -3359-.

–  Remove locking pin -3242-. –  Turn crankshaft two rotations in normal direction of rotation until it is set to TDC of No. 3 cylinder again. –  Recheck markings at toothed belt tensioner. Correct toothed belt tension as necessary. –  Install vibration damper on injection pump sprocket (bolts -1-).

–  Tightening torque: 20 Nm

–  Install front section of intake manifold → Chapter. –  Attach electrical connector on injection pump (make sure connector engages properly). –  Connect fuel supply and return pipes. After installing the injection pump, the following steps must be performed: l  Bleed fuel system, otherwise engine will not start → Chapter. l  Dynamically check and adjust commencement of injection → Chapter. Additional step for vehicles as from model year 2002: l  The new injection pump must be adapted to the immobiliser (otherwise engine will not start). The procedure required after installing the new injection pump is described in the Guided Fault Finding or Guided functions. –  Install toothed belt cover.