Removing and installing high-pressure pump and gear-type fuel system pressurisation pump — AUDI

🧭 Before you start

Access work: engine cover off, cooling system drained, lock carrier in service position, left intake manifold, EGR valve and EGR cooler removed. Then the high-pressure pipes (counterheld at the pump), banjo bolts, return hose and fuel distributor housing with bracket come off, followed by the pump's toothed belt and rear cover, the pump with its front bracket, the central nut and the sprocket. Installation reverses this with new seals, pipe unions tightened hand-tight first and torqued with the 14 mm socket once free of tension, then cooling system filled, jacking mode deactivated, headlights adjusted, fuel system bled and checked for leaks.

Fits: Audi A8 D3 (4E, 2002–2010)

• Opens: coolant
• Special tools named: T40064, puller
• Renewed: seals

Don't miss

• Read the fuel system working instructions before starting and follow them throughout.
• Counterhold at the pump pipe connections when removing the high-pressure pipes.
• Use the counterhold tool on the central nut and a puller for the sprocket; do not lever it off.
• Renew all seals; refit hose clips of the original type.
• High-pressure pipe unions hand-tight first, pipes free of tension, then torque.
• Bleed the fuel system before the first engine start, then check for leaks.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ Always read instructions for working on fuel system.Follow these instructions before starting work and while working on the fuel system . — Remove engine cover panel (refer to instructions for removing and installing ).
2. Drain cooling system. 19
3. Move lock carrier to service position. General body repairs, exterior50
4. Remove intake manifold (left-side). 15
5. Remove mechanical exhaust gas recirculation valve (left-side). 26

6. Remove cooler (left-side) for exhaust gas recirculation. 26
7. Unplug electrical connectors (4) and (6).
8. Remove high-pressure pipes (1) and (2) (counterhold at pipe connections on high-pressure pump).
9. Remove banjo bolt (3).
10. Disconnect fuel return hose (5) at fuel distributor housing.
11. Remove bolts (7) and take off fuel distributor housing.
12. Unplug electrical connector (3).
13. Remove banjo bolt (2).
14. Remove bracket (1) for fuel distributor housing.
15. Remove toothed belt for high-pressure pump .
16. Release clamps (arrows) and lift off rear toothed belt cover (1).
17. Remove bolts (arrows).
18. Take off high-pressure pump together with front bracket.
19. Remove central nut for high-pressure pump (use counterhold tool T40053).
20. Pull toothed belt sprocket off high-pressure pump using puller T40064.
21. Remove bolts (arrows).
22. Take high-pressure pump off front bracket. [Note: Renew seals.Secure all hose connections with the correct type of hose clips (same as original equipment) Parts catalogue.]
23. Tighten union nuts on high-pressure pipes hand-tight initially.
24. Ensure that high-pressure pipes are not under tension.
25. To tighten unions of high-pressure pipes, use torque wrenchV.A.G 1331 with ratchetV.A.G 1331/1 and socket, 14 mm3150.
26. Install toothed belt for high-pressure pump .
27. Install cooler (left-side) for exhaust gas recirculation. 26
28. Install mechanical exhaust gas recirculation valve (left-side). 26
29. Install intake manifold (left-side). 15
30. Install lock carrier with attachments General body repairs, exterior50.
31. Install front bumper General body repairs, exterior63.
32. Fill cooling system. 19
33. Deactivate jacking mode. 43
34. Adjust headlights 94.
35. Bleed fuel system before first engine start .
36. Check fuel system for leaks .

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