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High Pressure Fuel Pump Cam Follower Maintenance 07 Audi A4

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  1. step : Removing the High Pressure Fuel Pump and Cam Follower (2:10)
    • Remove the plastic engine cover
    • Unclip the PCV breather tube
    • Pull off the PCV breather tube
    • Disconnect the two sensors from the high pressure fuel pump
    • Put a rag underneath the Schrader valve
    • Unscrew the Schrader valve cover
    • Press the Schrader valve with a flat screwdriver to release the pressure
    • Remove the Schrader valve with a 13mm wrench
    • Disconnect the hard fuel line from the bottom of the pump with a 17mm wrench
    • Remove the 8mm triple square banjo bolt, if present
    • Remove the rubber hose from the fuel pump
    • Remove the three T30 Torx screws from the pump
    • Pull the pump up and out
    • Pull out the cam follower
    • Check the cam follower for visible wear
  2. step : Installing the High Pressure Fuel Pump and Cam Follower (6:03)
    • Put the cam follower into place
    • Put the fuel pump into place
    • Insert the three T30 screws into the fuel pump
    • Connect the rubber hose to the fuel pump
    • Fasten the 8mm triple square bolt, if present
    • Put the hard fuel line into place
    • Tighten the 17mm nut for the hard fuel line
    • Make sure the Schrader valve is clean
    • Twist on the Schrader valve by hand
    • Fasten the Schrader valve with a 13mm wrench
    • Put the plastic cap on the Schrader valve
    • Connect the two sensors to the pump
    • Press on the PCV breather hose

Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Tony with 1A Auto, here to talk to you today about a very important part of maintenance on your 2.0 Turbo FSI Volkswagen or Audi motor. This cam follower, it's a minor detail, very important, and an often neglected part of maintenance that can lead to catastrophic failure if left unattended too long.

These motors, like in the '07 Audi A4 behind me, use direct fuel injection which requires a great amount of fuel pressure. This little pump here is a mechanical fuel pump that sits on the top of the engine and rides against the lobe on the back of them cam. As that cam moves in and out, this follower compresses and releases the pump to build the pressure it needs.

One very common fault we see with these is the end of the cam follower wearing down or in extreme cases, wearing a hole directly through the other side. That can cause the end of the high pressure fuel pump to ride directly on your cam shaft lobe. This can cause anywhere from check engine lights - some common codes are P0087, P1093 and P2293. It can cause loss of power, low fuel pressure and in extreme cases, the metal on metal can get shavings into the motor and cause catastrophic engine failure.

Volkswagen and Audi don't have a specific service interval at this time. We strongly recommend you inspect your cam follower every twenty thousand miles under normal driving conditions and under heavy driving conditions or spirited driving, we recommend you check every ten to fifteen thousand if not every oil change.

Items you will need for removal and re-installation: flat blade screwdriver, thirteen millimeter wrench, seventeen millimeter stubby wrench, needle nose pliers or an eight millimeter triple square depending on what style pump you have, and a T30 Torx driver.

Remove the plastic cover on top of the engine by pulling it up. The high pressure fuel pump is located on the transmission side. This will be the rear in longitudinal mounted motors, Audis and Passats, and on the driver's side in transverse mounted engines, GTIs, Jettas and Golfs.

We're going to remove the PCV breather tube to make it easier to show you what we're doing and also it can give you a little more room to work if you'd like. Squeeze the ends of the tubes. Pop them off the retainers. Be careful because this plastic is very brittle.

Remove the two connectors on your high pressure fuel pump. You want to pull back carefully on the clips and release. Remove the protective cover on the Schrader valve by unscrewing it. Place a rag or paper towels underneath the Schrader valve. These high pressure fuel pumps can create up to 1,800 PSI of pressure, so be careful, wear you safety glasses and always release the fuel pressure before working on the pump.

I'm just going to go ahead and push that valve a few times to make sure all that fuel is out of there. Use a thirteen millimeter wrench to undo your Schrader valve. Always stay back just in case there's still some pressure there. We're going to leave our rag in case there's still a little bit of fuel. Be sure to store your Schrader valve somewhere clean while working.

We're going to use a seventeen millimeter stubby wrench to disconnect the hard fuel line on the bottom of the pump. Once it's loose, the rest should come undone by hand. This high pressure fuel pump is the newer style. So we'll remove the rubber hose on the bottom of the pump. If you have an earlier model, you'll have an eight millimeter triple square banjo bolt down here that you'll have to remove with a ratchet.

Remove three T30 Torx screws. This bottom one will be located behind the Schrader valve that we removed earlier. Remove the high pressure fuel pump assembly from the top of the motor.

Remove the cam follower. We went ahead and inspected our cam follower. Everything looks good so we're going to put it back in and check it again soon.

Reinstall the high pressure fuel pump. Reinstall our three T30 bolts. Reinstall your rubber fuel line. Line up your hard line and start the nut by hand. Finish snugging it up with a seventeen millimeter stubby wrench. This is a brass fitting. There's no need to go crazy tight. Be sure you Schrader valve is free of dirt, debris or any other kind of blockage before re-installing. Finish tightening with a thirteen millimeter wrench. Reinstall your protective plastic cap. Reconnect the two sensors. Reconnect your PCV breather by simply pressing it on until it clicks.

Thanks for tuning in. We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    Materials, Fluids, and Supplies

  • Cloth Rags

  • Pliers, Cutters & misc Wrenches

  • Needle nose pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Specialty Tools

  • 8mm Triple Square Driver

  • Star Drivers & Sockets

  • T30 Driver

  • Wrenches - Metric

  • 13mm Wrench
  • 17mm Wrench


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