Tips for Removing 8mm Triple Square Banjo bolt for HPFP- Cam Follower?

[DluA]

Greetings Audi Vets & Enthusiasts!

A month ago, I bought a 2006 Audi A4 2.0T Quattro (Brilliant Red) with 201k. With help from my dad, we have replaced the power steering rack due to 3 different tears in the bellows causing leaks, replaced the timing belt and water pump, serpentine belt, and a handful of other maintenance related issues, including oil, coolant, air filter changes.

We realize it's critical to check the cam follower within the high pressure fuel pump (HPFP), BUT... we can't seem to be able to remove the 8mm Triple Square Banjo bolt from the HPFP. HELP!!

We purchased 2 different Triple Square bits and played with various lengths of extenders for sockets, but still can't seem to crack it. We're even more concerned about tightening it once loose.

I've read through some stickies and searched for a bit, BUT... please, any advice for this Audi novice would be GREATLY appreciated!

Perhaps a stubby bit and socket set for the triple square or simply 1/4" extenders???

Thanks in advance,
DluA (James)

[KMPRSSD]

The trick is to get the bit to sit fully and square in the bolt. Its been a while since I have done a cam follower, but a combination of wobble or universal joint sockets and lengths should give you the correct angle. You can also try a touch of penetrating oil on it overnight. Also are you quite sure it is a triple square?? I don't seen to remember it being one.

[Jeevan]

If you don't have experience in removing the banjo, I would suggest you to buy a couple banjo bolts before starting this. If the banjo bolt falls down into the black hole of the engine bay, it's hard to find. You don't have to buy any special stubbies. All you need is about 12-15 inch long 3/8 or 1/4 extension depending on the socket. You need to move the coolant tank and pcv breather hoses aside, put the socket with extension from rear( bottom side of the engine). Use a screw driver to guide the socket into the bolt, a magnet to catch the bolt before it falls off. People say you need some electrical tape I'm the tip of the socket to hold the bolt firm but I don't like that as it's a bad way to strip a bolt.

Watch this video.

https://youtu.be/XJ7wcj7oi_4

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[Jeevan]

First time, it's feels like there is no way that a socket and extension will fit in the tight place. If you are using 3/8 socket, hold the socket with magnet near the bolt then push the extensions from the bottom to clip into the socket.


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[DluA]

Appreciate the advice fellas! I did find that video previously, but will try again. Thanks for the input about having multiple banjo bolts and using a magnet upon disconnecting.

[IbisB7stage2]

If jeevans ideas don't work, pull the intake manifold off. It's way easier then you think, gives more access to the banjo, and you'll want to check carbon build up on the intake valves.

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[Jeevan]

If jeevans ideas don't work, pull the intake manifold off. It's way easier then you think, gives more access to the banjo, and you'll want to check carbon build up on the intake valves.

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Pulling the intake? It clearly takes around 2 hours to do it if he had never done it before. Not to mention, a bunch of tricky bolts which needs magnets and 1/4 sockets, Changing injector seals. Either way, OP is better of using 1/4 extensions and sockets

It's a good idea to clean the carbon buildup but I hope he has time for scraping it. I did mine last week first time In it's 160k mile lifetime, it took me 3 hours to scrape off the buildup with powertools and screw drivers lol( I don't have an air compressor to do media or walnut blasting)

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[vvenom800tt]

Greetings Audi Vets & Enthusiasts!

A month ago, I bought a 2006 Audi A4 2.0T Quattro (Brilliant Red) with 201k. With help from my dad, we have replaced the power steering rack due to 3 different tears in the bellows causing leaks

Thanks in advance,

DluA (James)

Let get one thing straight before you and your dad go on a voyage together.

The boots on the power steering rack are not there to keep fluid in. They are there as dust boots for the inner tie rod.

The fluid in the rack is contained by seals the are further inboard than the dust boot.

Make sure you know what parts do before you get all excited about stuff and potential spread misinformation.

End rant/

Now the banjo bolt, i dont know, i ditched mine and replaced it with the soft line on the later model B7.

[DluA]

Greetings Audi Vets & Enthusiasts!

A month ago, I bought a 2006 Audi A4 2.0T Quattro (Brilliant Red) with 201k. With help from my dad, we have replaced the power steering rack due to 3 different tears in the bellows causing leaks,

I've read through some stickies and searched for a bit, BUT... please, any advice for this Audi novice would be GREATLY appreciated!

Venom,

While you are right that I did a poor job of explaining the reason for the PS leaks, let's also get straight that I clearly called myself an Audi NOVICE
If you're taking what a brand new member said as gospel, then forums in general are probably NOT the place for you. With that said, thanks for your insight on the banjo bolt!

Cheers

[vvenom800tt]

Venom,

While you are right that I did a poor job of explaining the reason for the PS leaks, let's also get straight that I clearly called myself an Audi NOVICE
If you're taking what a brand new member said as gospel, then forums in general are probably NOT the place for you. With that said, thanks for your insight on the banjo bolt!

Cheers

Im not taking it as gospel at all. Im just helping you understand what that part is there for. Novice or not, take it on the chin and consider it tough love.

Scrap the banjo bolt and get the parts to convert it to the new style barb. It'll save a lot of headache.

Fuel line
Soft hose
Barb fitting

Thats all you need to convert it.

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[Theiceman]

The banjo bolt is easy literally 10 seconds.
But you need to know the trick.
Triple square bit on a 12 inch extension. Go way down and hook under everything ..
Use a telescoping magnet to grab it as it comes out. Done.

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[DluA]

Appreciate it fellas! Thanks for all the responses!

I have 06D-109-309 C as the OEM P/N. Anyone recommend anything different for replacing the follower?

Thanks again.


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[vvenom800tt]

Just get an INA follower. Been using them for years with no issues. And theyre about half the price of oem.

Also on sale at ecs now.

I literally just ordered one 5 minutes ago. Don't buy the kit its overpriced, get the follower and pump gasket individually and its not even $30 total.

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[Theiceman]

Because i am asked about this so often i just went down and snapped a couple of pics. it literally took me longer to take the pics than to get onto the banjo. One more tip . people get paranoid because it is fuel , do NOT over reef this thing. snug and a little extra is fine.

tools needed .



pics of how to access..







you can even easily get a torque wrench on here if it makes you feel better.

don't have to move coolant take or anything..

there is a line of sight spot from above just stick your magnet in and grab the bolt as it comes out. i put it back in that way too and bring the bit up to meet it when i put it back together.

[DluA]

VVenom- you saved me time and money! Bought 2 of each. Always nice to hit the discounted pricing. Once again, I thank you!


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[DluA]

Iceman- wow! Beyond what I expected anyone to respond with! You are the man! I’m sure this time and effort you took will serve many that come across this thread. I’ll let you know once we replace the follower and hopefully find this bolt to be “old hat.” Or replace it all together as VVenom suggested. I’ll be your wingman anytime! Maverick. lol


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[Theiceman]

Iceman- wow! Beyond what I expected anyone to respond with! You are the man! I’m sure this time and effort you took will serve many that come across this thread. I’ll let you know once we replace the follower and hopefully find this bolt to be “old hat.” Or replace it all together as VVenom suggested. I’ll be your wingman anytime! Maverick. lol


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actually this comes up a fair bit... i just never bothered to do the pics, you motivated me .. people think having that banjo bolt is a bad ting, until they realize its way quicker than the rubber hose version where you are fighting the pump becasue the rubber hose stays attached. .
oh be VERY careful tightening the three fuel pump bolts, snug is all you need, they strip out VERY easily out of the timing housing.

[Jayz691]

I also always use INA followers. Theyre like $15 on FCP, and only need to pays for 1. Then use their lifetime free replacement. But I like haveing the rubber hose, I leave it on ta do the follower. Just remove hardline, valve, 3 screws, and remove.

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[DluA]

Everyone- Thank you for the advice and ESPECIALLY want to thank ICEMAN for the detailed pictures that turned this banjo bolt into a breeze. Ordered the INA follower and gasket from ECS. Not too bad after that. Seems like I should get some mileage from this follower based upon my driving habits... Cheers!

[Theiceman]

Everyone- Thank you for the advice and ESPECIALLY want to thank ICEMAN for the detailed pictures that turned this banjo bolt into a breeze. Ordered the INA follower and gasket from ECS. Not too bad after that. Seems like I should get some mileage from this follower based upon my driving habits... Cheers!

great work !!! pretty easy once you figure out the angle right !!!?? :)

[Nizmo]

Might sound silly but having both styles of these HPFP's I'd rather the banjo style. I hate fighting the rubber line.

[Jayz691]

Might sound silly but having both styles of these HPFP's I'd rather the banjo style. I hate fighting the rubber line.

The nice thing though is if ya don't need to actually remove the pump, ya font have to touch the rubber line. Like just checking/changing follower, I leave it attached.

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[mc_hotmail]

I removed my '07 BWT engine HPFP twice, but both time left the bottom hose attached. You don't need to remove it like the JHms video to replace the follower.

[aluthman]

I always use two long extensions and come up from down my the axle like pictured above. I prefer working on the banjo bolt setup over the soft line.

[Theiceman]

bumping this as this has come up again.