Audi Workshop Service and Repair Manuals

Removing and installing high-pressure pump Special tools and workshop equipment required

t  Locking pin -3242-

t  Adapter -T40058-

t  Locking pin -T40245-

t  Counterhold tool -T40248- Removing –  Remove intake manifold → Chapter. –  Remove turbocharger → Rep. gr.21. –  Remove engine oil cooler → Rep. gr.17. –  Remove coolant shut-off valve → Rep. gr.19.

–  Unscrew bolts -arrows- and swivel bracket -1- for turbocharger to side.

–  Remove rear noise insulation panel -1- → Rep. gr.66.

–  Insert guide pin of adapter -T40058- as follows: l  The larger-diameter section -arrow 1- faces towards the engine. l  The smaller-diameter section -arrow 2- faces the adapter.

Caution Irreparable damage can be caused if the camshaft timing chain slips. Turn crankshaft only in direction of engine rotation -arrow-. –  Use adapter -T40058- to turn crankshaft to „TDC“ position.

l  Mark -arrow- must be perpendicular to centre of crankshaft, as shown in illustration.   Note

Place a cloth beneath the sump (top section) to catch escaping oil. –  Unscrew plug -arrow- for „TDC“ marking from sump (top section).

–  Screw locking pin -3242- into hole (20 Nm); if necessary, turn crankshaft -1- backwards and forwards slightly to fully centralise locking pin.

–  Lock chain sprocket for high-pressure pump in position using locking pin -T40245-.   Caution Risk of malfunctions caused by dirt. Observe → Chapter „Safety precautions when working on the fuel system“.

–  Unscrew union nuts -arrows- and detach high-pressure pipe (right-side) -1-.

–  Unscrew union nuts -arrows- and detach high-pressure pipe (left-side) -1-. –  Seal off open lines and connections with clean plugs.

–  Unplug electrical connector -2-. –  Release hose clips -3 and 4- and detach fuel hoses.   Note Lay a cloth under the connection to catch escaping fuel.   Note Disregard -item 1-.

–  Unscrew bolts -arrows- and detach high-pressure pump. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter „High-pressure pump - exploded view“   Note Always renew high-pressure pipes when renewing high-pressure pump.

–  When renewing high-pressure pump, install adapter from old high-pressure pump on new pump. –  Use counterhold tool -T40248- to loosen and tighten nut -arrow-.

–  Insert high-pressure pump into chain sprocket. l  The dual toothing -arrow A- on the chain sprocket must align with the groove -arrow B- in the adapter on the high-pressure pump shaft. –  Remove locking pin -3242- and locking pin -T40245-. –  Tighten plug for „TDC“ drilling in sump (top section) → Rep. gr.17. –  Install high-pressure pipes → Chapter. –  Install coolant shut-off valve → Rep. gr.19. –  Install engine oil cooler → Rep. gr.17. –  Install turbocharger → Rep. gr.21. –  Install intake manifold → Chapter. –  Install rear noise insulation → Rep. gr.66.   Caution Running when dry causes irreparable damage to high-pressure pump. After installing the high-pressure pump, the pump must first be filled with fuel before the engine is started for the first time → Chapter.