High pressure pump, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - High Pressure Pump, Removing And Installing

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Special tools, testers and auxiliary items required

Socket 14 mm 3150
Torque wrench V.A.G 1331
Ratchet V.A.G 1331/1
Socket T40055

Removing

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure → Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention! .
Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

Drain coolant → 19 - ENGINE - COOLING SYSTEM .
Remove front coolant pipe → 19 - ENGINE - COOLING SYSTEM .
Remove upper part of intake manifold → Intake manifold upper-part, removing and installing .

Fig 2: Removing Bolts & Union Nuts

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Remove bolts - 1 through 4 - and - 7 -.
Loosen union nuts - 5 - and - 6 -.

Fig 3: Removing Large Lifting Eye

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If equipped, remove large lifting eye - arrows -.

Fig 4: Disconnecting Electrical Connector

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Disconnect electrical connector - 2 -.

NOTE:

Ignore - 1 -.

Remove bolts - arrows -.
Carefully lift high pressure lines.

NOTE:

Do not change bend shape.

Remove high pressure pump with actuator.

Installing

Installation is in reverse order of removal, note the following:

NOTE:

Replace O-ring.

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

NOTE:

High pressure line connections must not show any signs of damage.
Do not change bend shape of high pressure lines.

Place high pressure pump with actuator into cylinder head and fasten.
Hand-tighten union nuts for high-pressure lines.
Make sure high-pressure lines are seated free of stress.

Fig 5: Fastening High-Pressure Line (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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (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.

Fig 6: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 Mm T40055

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (17 mm) to high pressure pump, use Torque Wrench V.A.G 1331 with Reversible Ratchet V.A.G 1331/1 and Socket T40055.
Install intake manifold upper-part → Intake manifold upper-part, removing and installing .
Install front coolant pipe → 19 - ENGINE - COOLING SYSTEM .
Fill with coolant → 19 - ENGINE - COOLING SYSTEM .

Torque specifications

Component	Nm
High pressure pump to cylinder head	10
High pressure lines to high pressure pump	25