Fuel Line High-Pressure Pump: Audi's Secret Weapon

The high-pressure fuel pump (HPFP) in an Audi is a cam-driven fuel pump that provides over 1500 psi to the direct injection fuel injectors in the engine. The HPFP is mounted on the driver's side of the cylinder head and is driven by the camshaft. Audi vehicles with 2.0t engines utilize two fuel pumps: a high-pressure pump driven by the engine and a low-pressure pump situated in the fuel tank. When the fuel pump fails, it can cause faults related to fuel pressure and fault codes such as P2293 and P0087. Replacing the fuel pump can be a complex task and may require specialized tools and knowledge, so it is recommended to consult a professional or a mechanic if you are unsure about the process.

Audi A4 B7 2.0t Quattro (2005-2008) low-pressure fuel pump replacement

Overview

The Audi A4 B7 2.0t Quattro (2005-2008) utilises two fuel pumps: a high-pressure pump driven by the engine and a low-pressure pump situated in the fuel tank. This guide will cover the process of replacing the low-pressure fuel pump (LPFP). It is important to note that the process for the Quattro model is slightly different from the non-Quattro A4 B7, and this guide will focus specifically on the Quattro version.

Tools Required

• Phillips head screwdriver
• Special fuel line pliers
• Black Sharpie permanent marker
• Fuel tank wrench (optional)

Step 1 – Prepare the Vehicle

Before beginning the replacement, ensure that your fuel tank is below 1/4 full. It is recommended to have as little fuel as possible to prevent spillage during the pump removal. Disconnect the battery to prevent any sparks or ignition sources. It is also suggested to change the fuel filter when replacing the pump.

Step 2 – Remove Rear Seat Bottom

Firmly pull up on the front of the rear seat at the 1/4 and 3/4 points across the width to release the connectors. If your vehicle is equipped with rear seat heaters, carefully lift the rear seat bottom to access and disconnect the wires. Set the seat bottom aside to allow easier access to the pump area.

Step 3 – Disconnect Pump

Locate the pump cover on the passenger side, where the back seat cushion would normally sit. Remove the three Phillips head screws and the plate. Find the pump assembly head. Disconnect the fuel line at the fuel filter, which is located in the front of the passenger side wheel well, to relieve the fuel line pressure. Use a bucket to collect the fuel as you release the pressure. Clean the area around the fuel pump head using compressed air and vacuum, or any other suitable method. Disconnect the power connector from the fuel pump head. To disconnect the fuel lines, push down on the gas line fitting and use modified needle nose pliers or small flat tip screwdrivers to squeeze the side catches, then pull up on the fuel line. Disconnect both fuel lines.

Step 4 – Remove the Pump

Use a Sharpie marker to mark the fuel pump ring and the fuel tank to ensure proper alignment during reassembly. Using a fuel tank wrench, turn the fuel pump ring counterclockwise to release it from the tank. Alternatively, you can use a flat tip screwdriver and a hammer to lightly tap the ring until it releases. Pull up on the pump head slightly to access the rest of the pump inside the tank. Disconnect two more tubes: a thinner black line and a thicker ribbed line. The thinner line is a push, squeeze, and pull type disconnect, while the thicker line can be pulled out directly. Carefully remove the rest of the pump from the tank, being mindful of any remaining fuel spillage.

Step 5 – Install New Pump

Place the lower portion of the new fuel pump into the fuel tank, ensuring the upper portion remains aside. Be cautious not to damage the fuel level sender. Reconnect the two pipes inside the tank that were disconnected in the previous step. Make sure the top and bottom parts of the fuel pump are firmly connected. Maneuver the new tank gasket over the fuel pump head and fit it to the fuel tank with the ribbed side up. Place the fuel pump head back into the hole and secure it with the fuel pump ring, orienting it as it was originally positioned. Reattach the two lines and wiring.

Step 6 – Start the Car

Reconnect the battery and turn the key to the "on" position without starting the engine. You should hear the pump run briefly. Briefly turn the key to the start position without attempting to start the engine, allowing the pump to run again. Repeat this process several times to prime the pump and fuel system. Attempt to start the car, and if necessary, give it several tries as the fuel system may still have some air in it. Once the engine starts and there are no leaks or issues, reinstall the fuel cover plate and rear seat, ensuring to reconnect the rear seat heaters if applicable.

Audi 2.0T FSI and 4.2L FSI engines

The high-pressure fuel pump (HPFP) in the Audi 2.0T FSI engine is a mechanical pump that runs off a lobe on the intake camshaft. It is located on the driver's side front of the engine at the top. The FSI pump is prone to failure, which may cause running issues and a check engine light. When the fuel pump fails, faults relating to fuel pressure may occur, including fault codes P0087 (fuel rail/system pressure too low), P1093 (fuel trim 2, bank 1 malfunction), and P2293 (fuel pressure regulator 2 performance). It is recommended to replace the cam follower when installing a new fuel pump.

The Audi 4.2L FSI engine requires two high-pressure fuel pumps. The IE HPFP upgrade kit for the 4.2L FSI engine offers 50% more displacement than the factory unit, delivering enough fuel flow for nearly 600hp at 7500rpm. This upgrade is popular for the Audi B8 4.2L S5 (2008-2013) and is necessary for stage 2 and big turbo FSI cars.

Audi A6 Quattro with 3.2L FSI engine, VIN No. WAUDG74F96N03xxxx

The Audi A6 Quattro with a 3.2L FSI engine and the VIN number WAUDG74F96N03xxxx was produced between 2004 and 2011. The high-pressure fuel pump (HPFP) in this model has been known to fail, which can activate a code that would lead to one of three things: the low-pressure fuel sensor, the high-pressure fuel sensor, or the HPFP itself.

To replace the HPFP, you will need a flat-head screwdriver and a Torx bit: T30. The process is as follows:

• Drain the coolant by placing a pan under the drain plug of the radiator and turning the drain plug counter-clockwise.
• Move the coolant crossover pipe by sliding the hose clamp off the small hose between the thermostat housing and coolant crossover pipe. Then, remove the mounting screws from both sides (2 on each side) and pull it forward to access the bottom screw for the HPFP.
• Remove the three bolts holding the HPFP in place and pull it out. If it is stuck, use a screwdriver to pry it loose.
• Install the new HPFP the same way the old one was installed and tighten the three screws.
• Reinstall the coolant crossover pipe and refill the radiator with coolant.
• With coolant in the system, remove the overflow tank cap, start the car, and let it run for 10 to 15 minutes to get rid of any bubbles. Then, refit the cap and test drive the car.

It is also recommended to replace the cam follower during the 55K service to avoid costly repairs if it completely wears out and causes unusual camshaft wear.

Audi A4 B7 2.0t Quattro fuel line pliers

The Audi A4 B7 2.0t Quattro engine uses two fuel pumps: a high-pressure pump driven by the engine and a low-pressure pump situated in the fuel tank.

When replacing the low-pressure fuel pump, you will need a Phillips-head screwdriver, special fuel line pliers, and a black Sharpie permanent marker. Before starting, ensure your fuel tank is less than a quarter full to avoid spillage inside the passenger compartment. It is also highly recommended to change the fuel filter when changing the pump.

Step 1: Remove the rear seat bottom. Pull up firmly on the seat at the front to release the connectors. If equipped with rear seat heaters, carefully lift the seat bottom to find and disconnect the wires.

Step 2: Disconnect the pump. Remove the three Phillips-head screws and the plate covering the pump assembly head. Disconnect the fuel line to relieve the pressure and collect the fuel in a bucket. Clean the area around the fuel pump head using compressed air and vacuum. Disconnect the power connector from the fuel pump head. Push down on the gas line fitting and squeeze the side catches with modified needle-nose pliers or small flat-tip screwdrivers. Pull up on the fuel line to disconnect it from the fuel pump head.

Step 3: Remove the pump. Use the Sharpie marker to mark the fuel pump ring and the fuel tank to align them when reassembling. Use a fuel tank wrench to turn the fuel pump ring counterclockwise and release it from the tank. Alternatively, use a flat-tip screwdriver and a hammer to lightly tap the ring until it releases. Pull up on the pump head to access the rest of the pump inside the tank. Disconnect two tubes: a thinner black line and a thicker ribbed line.

Step 4: Install the new pump. Place the lower portion of the new fuel pump into the fuel tank. Reconnect the two tubes inside the tank. Ensure the top and bottom parts of the fuel pump are firmly connected. Maneuver the new tank gasket over the fuel pump head and fit it to the fuel tank with the ribbed side up. Place the fuel pump head back into the hole and secure it with the fuel pump ring. Tighten the ring and reattach the two lines and wiring.

Step 5: Start the car. Prime the pump and fuel system by reconnecting the battery and turning the key to the "on" position without starting the engine. Briefly turn the key to the start position several times to ensure the pump is primed. Once started, reinstall the fuel cover plate and rear seat.

You can find fuel lines, fuel pumps, and other parts for the Audi A4 B7 2.0t Quattro on websites such as ECS Tuning and Amazon.

Audi A3 A4 TT Quattro VW Eos GTI Jetta Passat 2.0L TFSI

The high-pressure fuel pump is an essential part of your vehicle's engine system. It is responsible for pumping fuel from the gas tank to the fuel injectors for distribution into the engine. If your car's fuel pump fails, your vehicle won't be able to move gas from the tank to the engine, resulting in a lack of ignition, combustion, and forward motion.

Now, let's focus on the Audi A3, A4, TT Quattro, and VW Eos, GTI, Jetta, and Passat 2.0L TFSI models. Here's a detailed guide on the high-pressure fuel pump for these specific vehicles:

Vehicle Compatibility

The high-pressure fuel pump with part number 06F127025M or HPP0004 is compatible with the following vehicles:

• Audi A3 (2006-2008, 2007-2008 A3 Quattro)
• Audi A4 (2005-2009, 2005-2009 A4 Quattro)
• Audi TT Quattro (2009-2015)
• VW Eos (2007-2009)
• VW GTI (2006-2009)
• VW Jetta (2006-2008)
• VW Passat (2006-2008)

Specifications

• Connector Shape: Oval
• Fuel Type: Gas
• Bolt Included: Varies (check specific product listings)
• Gasket Included: Varies (check specific product listings)
• Seal Included: Yes
• Inlet Fitting Thread Size: M14-1.5
• Terminal Quantity: 2
• Terminal Type: Blade

Installation Tips and Considerations

When installing a high-pressure fuel pump, here are some important tips and considerations:

• Always check the fitment and part number before purchasing to ensure compatibility with your specific vehicle.
• Pay attention to the installation instructions. For example, some pumps require pre-tightening the bolts on both sides to adjust the pump body plunger perpendicular to the camshaft before final tightening.
• Consider replacing the cam follower when installing a new fuel pump, as recommended by some vehicle owners.
• Ensure you purchase a high-quality fuel pump from a reputable brand to avoid premature failure and potential engine damage.

Product Options

There are several options available for high-pressure fuel pumps compatible with the Audi and VW models mentioned:

• NOVAPARTS HPP0004 Electric High-Pressure Fuel Pump: This option offers a one-year unlimited-mileage service support and has received positive reviews for fit and functionality.
• A-Premium High-Pressure Fuel Pump: This pump is designed to meet OEM specifications and comes with a one-year unlimited-mileage guarantee.
• GELUOXI HPP0004 Direct Injection High-Pressure Fuel Pump: This pump offers a 12-month warranty and has received mixed reviews regarding quality and longevity.
• WATERWICH High-Pressure Fuel Pump: This option is a direct replacement for HPP0004 and has received a 5-star rating, although there are limited reviews.
• DrCax High-Pressure Fuel Pump: There is limited information about this product, but it appears to be a direct replacement for the OEM pump.

Please note that this list is not exhaustive, and it is always recommended to research multiple options before making a purchase decision.

Frequently asked questions