Removing and installing injection pump — AUDI

🧭 Before you start

Fits: platform codes 70A, 70B, 70C, 70E, 70H, 70J, 70K, 70L, 70M, 7DA, 7DB, 7DC, 7DE, 7DH, 7DJ, 7DK, 7DL, 7DM

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: puller

Don't miss

• Always remove injector line set complete; do not change bending shape
• Marks (arrows) on injection pump pulley/bracket (C) and flywheel/clutch housing (A) or drive plate/clutch housing (B) must align
• This condition is only achieved every 2nd complete rotation of crankshaft.
• Loosen injection pump pulley securing nut approx. one turn with counterhold tool3036.
• Mark direction of rotation of toothed belt

🔧 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.

📐 20 workshop diagrams for ACV

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove radiator grille. 66
2. Remove bracket for charge air cooler (1) (engine codes ACV, AUF, AYC only).
3. Unscrew securing bolts from lock carrier plate (2) on left and right.
4. Fold lock carrier with radiator(s) forwards.
5. Remove noise insulation tray.

6. Remove toothed belt guard for injection pump drive.
7. Remove injector pipes using open ring spanner3035. [Note: Always remove injector line set complete; do not change bending shape]
8. Cover openings with a clean cloth.
9. Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder:
10. Marks (arrows) on injection pump pulley/bracket (C) and flywheel/clutch housing (A) or drive plate/clutch housing (B) must align
11. Marks (arrows) on injection pump pulley/bracket (C) and flywheel/clutch housing (A) or drive plate/clutch housing (B) must align [Note: This condition is only achieved every 2nd complete rotation of crankshaft.]
12. Set accelerator position sender G79 to 82 mm (arrow A), left notch of vernier scale is reference point
13. Screw in accelerator position sender G79 as shown; turn crankshaft until TDC mark on flywheel/drive plate aligns with edge of accelerator position sender G79(arrow B) and marks on injection pump pulley and bracket also align [Note: This condition is only achieved every 2nd complete rotation of crankshaft.]
14. Loosen injection pump pulley securing nut approx. one turn with counterhold tool3036.
15. Remove belt tensioner and idler roller.
16. Mark direction of rotation of toothed belt
17. Remove toothed belt from camshaft and injection pump toothed belt pulleys.
18. Set injection pump pulley under tension with puller3032. [Note: Screw two socket head bolts 3032/13 (1) into threaded holes of injection pump pulley instead of the puller.]
19. Release injection pump pulley from taper of injection pump by striking spindle of puller (arrow) gently.
20. Remove injection pump pulley.
21. Disconnect 10-pin injection pump connector and knock connector out of retainer.
22. Unscrew securing bolts (1) and conical nut (2) from bracket.
23. Remove injection pump.
24. Lock injection pump at commencement of injection . [Note: New injection pumps are already locked at commencement of injection.]
25. Insert injection pump into bracket.
26. Tighten new securing bolts (1) to 24 Nm and conical nut (2) to 25 Nm. [Note: Commencement of injection is set dynamically using fault readerV.A.G 1551.] — 24 Nm (18 lb-ft)
27. Install injection pump pulley. When installing observe woodruff key seating.
28. Tighten securing nut to 90 Nm. Use counterhold tool3036 for this. [Note: When tightening the securing nut, ensure that no torque is transmitted to the injection pump shaft, which is locked at commencement of injection.] — 90 Nm (66 lb-ft)
29. Remove drive pulley for injection pump with counterhold tool3036.
30. Check whether TDC mark on flywheel and reference mark are aligned.
31. Fit toothed belt onto injection pump pulley.
32. Fit injection pump drive pulley into toothed belt and secure gear on camshaft so that the gear can still turn.
33. Install idler roller (1).
34. Turn idler roller so that indicator aligns with flange contour of cylinder head (arrow).
35. Tighten securing nut (2) to 20 Nm. — 20 Nm (15 lb-ft)
36. Install belt tensioner (1) so that belt tensioner tab seats in cut-out on bracket (arrow B).
37. Tighten securing bolt hand-tight.
38. To tension toothed belt, turn belt tensioner anti-clockwise until both indicators are aligned -arrow A.
39. Tighten securing bolt to 15 Nm. — 15 Nm (11 lb-ft)
40. Tighten injection pump drive pulley securing nut to 160 Nm. Use counterhold tool3036 for this. — 160 Nm (118 lb-ft)
41. Loosen locking bolt (2) on injection pump.
42. Insert intermediate plate (1) and tighten locking bolt to 12 Nm. — 12 Nm (8.9 lb-ft)
43. Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
44. The marking on the injection pump pulley must align with the marking on the injection pump (arrows). If injection pump pulley marking is not visible, turn crankshaft one turn further.
45. Check position of indicators (arrow A). The indicators must align. If the indicators do not align, but the front indicator is located within the underlying sheet metal contour, this is permissible. [Note: If the front indicator lies outside of the underlying sheet metal contour, the tensioning process must be repeated.]
46. Install toothed belt guard.
47. Fill injection pump with clean diesel fuel at return line connection. Capacity for new pump must be at least 180 ml.
48. Connect injection pipes, fuel pipes and electrical cables.
49. Dynamically check commencement of injection and adjust if necessary .
50. Fold lock carrier with radiator(s) backwards.
51. Tighten securing bolts for lock carrier plate (2) to 25 Nm on left and right. — 25 Nm (18 lb-ft)
52. Install bracket for charge air cooler (1).
53. Tighten securing bolts to 10 Nm. — 10 Nm (7.4 lb-ft)
54. Install radiator grille 66.

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• Checking intake manifold temperature sender
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