Audi Workshop Service and Repair Manuals

Removing and installing high-pressure pump

Special tools and workshop equipment required

t	Socket, 14 mm -3150-

t	Torque wrench -V.A.G 1331-

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

t	Socket -T40055-

Removing   WARNING t  The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system → Chapter. t  A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. –  Drain off coolant → Rep. Gr.19. –  Remove coolant pipe (front) → Rep. Gr.19. –  Remove intake manifold (top section) → Chapter.

–  Unscrew bolts -1 to 4- and -7-. –  Loosen union nuts -5- and -6-.

–  If fitted, unscrew the large lifting eye -arrows-.

–  Unplug electrical connector -2-.   Note Disregard -item 1-. –  Remove bolts -arrows-. –  Carefully lift high-pressure pipes.   Note Do not bend pipes to a different shape. –  Take off high-pressure pump together with plunger. Installing Installation is carried out in the reverse order; note the following:   Note Renew O-ring. –  Only lift high-pressure pipes slightly to fit the high-pressure pump.   Note t  The connections of the high-pressure pipes must not be damaged. t  Do not attempt to bend high-pressure pipes to a different shape. –  Insert high-pressure pump with plunger in cylinder head and tighten. –  Tighten union nuts on high-pressure pipes hand-tight initially. –  Ensure that high-pressure pipes are not under tension.

–  To tighten union of high-pressure pipe (14 mm) at high-pressure pump, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket, 14 mm -3150-.

–  To tighten union of high-pressure pipe (17 mm) at high-pressure pump, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket -T40055-. –  Install intake manifold (top section) → Chapter. –  Install coolant pipe (front) → Rep. Gr.19. –  Fill cooling system → Rep. Gr.19. Tightening torques

Component	Nm
High-pressure pump to cylinder head	10
High-pressure pipes to high-pressure pump	25