High Pressure Pump: Installing

WARNING: This page is about a different variant/trim than selected.

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-

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-- 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

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-- 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-

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

NOTE:

Check fuel system for leaks.