High Pressure Pump: Installing

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

Installation is performed in reverse order of removal, noting the following:

NOTE:

High pressure line connections must not show any signs of damage.

Do not change the angles of the fuel lines.

Never bend any of the fuel line mounting clamps.

If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

-- Replace the O-ring for the high-pressure pump.

-- Check the plunger -1- for damage and replace it if necessary.

Fig 1: Plunger -1-

Courtesy of AUDI OF AMERICA, LLC

-- Coat the plunger with oil and insert it with the tab -arrow A- in the guide -arrow B-.

NOTE:

To insert the high pressure pump, the roller tappet must be at its lowest point.

-- Rotate the crankshaft in the direction of engine rotation at the vibration damper bolt while pressing the roller tappet into the cylinder head until it reaches the deepest point.

-- Only lift the high pressure line slightly to insert the high pressure pump.

-- Install the high pressure pump into the housing.

-- Tighten the bolts -arrows- hand-tight until they contact the flange.

Fig 2: Identifying High-Pressure Fuel Pump Components

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts diagonally (approximately 1 turn until they touch the high pressure pump) with the necessary tightening specification.

NOTE:

Tightening the bolts on one side at time will damage the pump.

Tightening specification, refer to HIGH PRESSURE PUMP OVERVIEW

-- Tighten the union nut -5- on the fuel return line hand-tight. Align so it is free of stress.

-- Connect the fuel supply line -2-.

-- Tighten the bolts -3- and -4- on the hose clamps.

Fig 3: Identifying High-Pressure Fuel Pump Components

Courtesy of AUDI OF AMERICA, LLC

-- Connect the connectors -1- and -6-.

-- Tighten the high pressure line to the tightening specification Figure.

Fig 4: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench VAG 1331 With Ratchet VAG 1331/1 And Socket 14 mm 3150

Courtesy of AUDI OF AMERICA, LLC

-- Install the shield -1-.

Fig 5: Nuts -Arrows- And The Protective Plate -1-

Courtesy of AUDI OF AMERICA, LLC

-- Install the air filter housing lower section. Refer to LOWER AIR FILTER HOUSING .

NOTE:

Check fuel system for leaks.