Audi Workshop Service and Repair Manuals

Removing and installing high-pressure pump - vehicles up to 09.2005

Special tools and workshop equipment required

t	Puller -3032-

t	Counterhold tool -3036-

t	Puller -T40064-

Removing   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. –  Remove intake manifold (top section) → Chapter. –  Remove bottom section of intake manifold (left-side) → Chapter. –  Remove toothed belt for high-pressure pump → Chapter.

–  Remove central nut -1- for high-pressure pump shaft (use counterhold tool -3036-).

–  Use puller -T40064- to pull off belt sprocket for high-pressure pump.

–  Remove bolts -arrows- and detach toothed belt cover (rear).

–  Remove bolts -arrow- and take off connecting pipe for exhaust gas recirculation.

–  Disconnect fuel supply line -2- and fuel return line -1- from high-pressure pump and move lines clear to the side.

–  Unplug electrical connector -1-. –  Remove bolts -arrows-. –  Take off high-pressure pump together with front bracket.

–  Remove bolts -arrows-. –  Detach front bracket from high-pressure pump. Installing Installation is carried out in the reverse order; note the following:   Caution A new high-pressure pump must first be filled with fuel before the engine is started. The high-pressure pump must not be allowed to run while still empty. Bleeding fuel system → Chapter   Note Renew gaskets and seals. –  Install toothed belt for high-pressure pump. –  Install bottom section of intake manifold (left-side) → Chapter. –  Install intake manifold (top section) → Chapter. –  Bleed fuel system and check for leaks → Chapter. Tightening torques

Component		Nm
Front bracket to high-pressure pump		23
High-pressure pump with front bracket to bracket (rear)		23
High-pressure pump with	M6	9
front bracket to engine	M8	23
Fuel supply and return lines to high-pressure pump		25
EGR connecting pipe to exhaust gas recirculation valve -N18-		9
Toothed belt cover (rear) to engine		9