High Pressure Pump: Installing

WARNING: This page is about a different car, the 2012 Audi Q5, 2011 Audi Q5, 2010 Audi Q5, and 2009 Audi Q5. 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:

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 O-ring for the high-pressure pump.

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

Fig 1: Checking Plunger

Courtesy of AUDI OF AMERICA, LLC

-- Coat 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 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 bolts -arrows- by hand up to the flange.

Fig 2: Identifying High-Pressure Fuel Pump Components

Courtesy of AUDI OF AMERICA, LLC

-- Tighten bolts diagonally to the tightening specification (approximately 1 turn until the bolts contact the high pressure pump).

NOTE:

Tightening on just one side (bending) can damage the pump.

Tightening Specifications. Refer to HIGH PRESSURE PUMP OVERVIEW .

-- Tighten fuel supply line union nut -5- by hand. Align so it is free of stress.

-- Connect fuel supply hose -2-.

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

Fig 3: Identifying High-Pressure Fuel Pump Components

Courtesy of AUDI OF AMERICA, LLC

-- Connect connectors -1 and 6-.

-- Tighten high pressure line to the tightening specifications. Refer to Figure

Fig 4: Fastening High-Pressure Line (14 mm) At High Pressure Pump Use Torque Wrench VAS1331 With Ratchet VAS1331/1 And Socket 14 mm 3150

Courtesy of AUDI OF AMERICA, LLC

-- Install protective plate -1-.

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

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

NOTE:

Check fuel system for leaks.