Audi Workshop Service and Repair Manuals

Removing and installing high-pressure pump   Caution t  Observe rules for cleanliness when working on the injection system → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system. t  Before fitting tooth belt, toothed belt sprocket for high-pressure pump must be locked in position using locking tool -T40135-. This is important to prevent oscillation of toothed belt. t  The 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. First fuel filling → Chapter. Removing –  Remove top section of intake manifold → Chapter. –  Remove toothed belt for high-pressure pump → Chapter.

–  Unscrew bolts -arrows- and remove protective plate for high-pressure pipe. –  Unscrew union nuts -1 ... 4- and move high-pressure pipes clear.

–  Unplug electrical connector -3-. –  Remove fuel supply hose -1- and fuel return hose -2-. –  Unscrew bolts -arrows- and detach high-pressure pump. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals and gaskets. t  Fuel return lines must not be kinked, damaged or clogged.

t  If toothed belt sprocket for high-pressure pump must be renewed, use puller -T40064- to pull it off.

t  Before fitting toothed belt, toothed belt sprocket -1- for high-pressure pump must be locked in position using locking tool -T40135-. This is important to prevent oscillation of toothed belt. t  Two TDC points must be aligned in order to correctly adjust toothed belt for high pressure pump.

t  TDC of crankshaft -1-

t  TDC of camshaft -arrow- l  Tightening torques → Chapter –  Install toothed belt for high-pressure pump → Chapter. –  Install high-pressure pipes → Chapter. –  Install top section of intake manifold → Chapter.   Caution t  The 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. First fuel filling → Chapter t  Running when dry causes irreparable damage to high-pressure pump. After renewing high-pressure pump and/or fuel pressure regulating valve -N276-, adaption must be performed. Use → Vehicle diagnostic tester.