High pressure fuel pump install issue

[medvedko]

Hey guys,


I got the high pressure fuel pump off in about 15 min, oiled the seal of the new pump went to install and will not seat flush back in the cylinder head. I have about a quarter inch gap and don’t wanna force the pump into the cylinder head?
Does the engine need to be rotated so that the can Follower can sit a little further in? Any tricks to do the install? Appreciate any help!

2010 A4 2.0t

[Smac770]

Yeah, you should turn the engine so the roller tappet is at it's most inserted position. From the repair manual: "To insert the high pressure pump, the roller tappet must be at its lowest point."
Always only turn the engine clockwise (direction of normal engine rotation) as viewed standing in front of the car looking at the engine. 24mm socket to fit on the crank bolt.

[medvedko]

Yeah, you should turn the engine so the roller tappet is at it's most inserted position. From the repair manual: "To insert the high pressure pump, the roller tappet must be at its lowest point."
Always only turn the engine clockwise (direction of normal engine rotation) as viewed standing in front of the car looking at the engine. 24mm socket to fit on the crank bolt.

Thwnks for the quick reply! Do all the sparkplugs need to come out so the engine can spin with a little more ease or can it do without?

[FR_A4]

Thwnks for the quick reply! Do all the sparkplugs need to come out so the engine can spin with a little more ease or can it do without?
Just turn it slowly with plugs in. Doesn't take much force.

[medvedko]

Just turn it slowly with plugs in. Doesn't take much force.

Awesome!

update- So I turned the crank finally getting the cam follower or cam lobe to the lowest point, did this like 4 times to confirm.
The hpfp still has about or a little less than a 1/4 inch gap?

Any of you get it to seat flush without serious persuasion?

Do I just put the bolts in and do little by little ”evenly” until it seats flush?

[FR_A4]

Have bot fone this but in general:
Compare to old pump. Check if you can push new pump plunger a bit manually, unless the directions say not too. Check if anything is missing or fell out.

[medvedko]

Yes, test fitted and compared old pump to confirm if anything is different. The old pump also has the same gap and will not just push in all the way, there seems to be resistance from the spring. I don’t know if there’s supposed to be pressure on that spring or some resistance before it gets bolted down? From 2 videos I watched the pump didn’t look fully seated “before” installing the bolts?
All I know is you don’t want to install the pump on the peak of the cam and set it to the lowest point.....not a peep that it will just sit flush when installed by pushing it in by hand?

[Smac770]

If you know the tappet is at its lowest possible point, then just go with it. From the repair manual:
2 - High Pressure Pump Bolt
❑ First tighten the bolts diagonally hand-tight, then to 5 Nm and then to 20 Nm.
❑ Do not tilt the high pressure pump

I think the real key is just don't torque one screw all the way and then start threading the other screw. Keep it balanced. Hell, I'll probably both to 5Nm, then both to 10Nm, then both to 20Nm. :-)
Is it pretty tough to push the pump down flush while you thread the screws in hand tight?

[medvedko]

Smac770, thanks for the instructions! I have not even attempted to try and thread a bolt thru. I will give it a try here shortly and let you all know the outcome, appreciate the torque specs !

Btw, where are you guys getting the manuals, Alldata?

[cuda2000]

Just tighten it down, it will be fine. I did this about a month ago, exact same as you. Tighten it down.

Sent from my SAMSUNG-SM-G891A using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

[Smac770]

erwin.audiusa.com
Audi's documentation site. Pay for a day, grab the PDFs.

[medvedko]

Success, thank you all for the help!
I could hand tighten down the pump until it was flush no problems. As mentioned I altered back and forth with the bolts and torqued in sequence.
Car starts smoother and quiet, the rest seems the same but only took it out for a mile.
Thanks again!