Removing and installing high-pressure pumps: Audi 5.2 (BSM, BUJ, CMPA, CTPA, …)

🧭 Before you start

Fits: platform code 42

• Renewed: o-ring for high-pressure pump, if necessary

Don't miss

• Do not bend fuel pipes to a different shape.Do NOT bend open retaining clamps for fuel pipe.If one of the retaining clamps has been bent open or the fuel pipe has to be renewed, the retaining clamps must also be renewed.
• The high-pressure pump can be damaged if it is tightened too much on one side (keep it straight).
• Check fuel system for leaks.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Fit protective cover on bodywork .
2. ⚠ The fuel system operates at extremely high pressure. This can cause injury.The fuel pressure in the high-pressure section of the injection system must be reduced to a residual pressure prior to opening the system. — Reduce fuel pressure in high-pressure section of injection system .
3. Remove intake manifold (top section) .
4. Remove high-pressure pipes from high-pressure pump.
5. Remove bolts (arrows).

6. Carefully pull out high-pressure pump (1). It is possible that the roller tappet may remain lodged inside. [Note: Do not bend fuel pipes to a different shape.Do NOT bend open retaining clamps for fuel pipe.If one of the retaining clamps has been bent open or the fuel pipe has to be renewed, the retaining clamps must also be renewed.] [Note: Renew O-ring for high-pressure pump.The connections of the high-pressure pipes must not be damaged.] [Note: The connections of the high-pressure pipe must not be damaged.Do not bend fuel pipes to a different shape.Do NOT bend open retaining clamps for fuel pipe.If one of the retaining clamps has been bent open or the fuel pipe has to be renewed, the retaining clamps must also be renewed.]
7. Renew O-ring for high-pressure pump.
8. Check roller tappet (1) for damage and renew if necessary.
9. Lightly lubricate roller tappet with oil and fit in cylinder head so that guide (2) is in correct position (arrow).
10. Fit high-pressure pump and press downwards in guide as far as stop.
11. Now tighten bolts (arrows) hand-tight in small steps.
12. Then initially tighten securing bolts alternately to 5 Nm (do not tilt high-pressure pump). [Note: The high-pressure pump can be damaged if it is tightened too much on one side (keep it straight).] — 5 Nm (3.7 lb-ft)
13. Install high-pressure pipe .
14. Install intake manifold (top section) . [Note: Check fuel system for leaks.]

Other AUDI procedures

• Removing and installing fuel delivery unit (right-side) with fuel pump G23
• Removing and installing coolant pipe (left-side) – Audi Q7
• Removing and installing timing chain covers (left and right)
• Renewing valve stem oil seals (cylinder head installed) – Audi
• Removing, installing and adjusting mounting for torque reaction support
• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures