High Pressure Pump: Installing

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2009 Audi S5, and 2008 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

Installation is in reverse order of removal, Note The Following:

NOTE:

Replace O-Ring.

-- Insert roller tappet in cylinder head.

NOTE:

To Insert The High Pressure Pump, The Roller Tappet Must Be At Its Lowest Point.

-- Rotate the crankshaft until the roller tappet is at the lowest point.

-- To set the high pressure pump in place, lift the high pressure lines only slightly.

-- Insert high pressure pump in cylinder head and tighten.

NOTE:

High Pressure Line Connections Must Not Show Any Signs Of Damage.

Do not change the angles of the high pressure lines.

-- Hand-tighten the union nuts for the high-pressure lines.

-- Make sure the high-pressure lines are seated free of stress.

-- To tighten 14 mm diameter union nut on high pressure lines, use Torque Wrench:V.A.G 1331 with Socket Insert AF 14, open ring:V.A.G 1331/8 .

Fig 1: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/8

Courtesy of AUDI OF AMERICA, LLC

-- To tighten union nut (17 mm diameter) on high pressure lines, use Torque Wrench:V.A.G 1331 with Socket Insert, AF 17:V.A.G 1331/6 .

Fig 2: Identifying SW 17 Union Nut At Fuel Rail, Torque Wrench V.A.G 1331 And SW 17 Socket V.A.G 1331/6

Courtesy of AUDI OF AMERICA, LLC

Tightening Specifications. Refer to HIGH PRESSURE PUMP ASSEMBLY OVERVIEW .

-- Observe safety precautions after connecting battery. Refer to BATTERY .

-- Reconnect electrical connectors on Low Fuel Pressure Sensor -G410- -1- and Fuel Metering Valve 2 -N402- -2-.

Fig 3: Disconnecting Electrical Connectors On Low Fuel Pressure Sensor G410 And On Fuel Metering Valve 2 N402

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Check fuel system for leaks.