Audi A2 1.6 FSI High Pressure Fuel pump

I cannot say as I haven't done this yet. Fortunately, the small hickups have been rectified on ours after sealing up the dip-stick tubes.

In all honesty, buying a set of orings and taking it apart isn't that much of a job (me thinks).

EDIT: It does appear that a special too with the right shape is needed to take it apart though. This appears to be the most difficult obstacle.
 
cigasė said:
Hi,

O-ring is 17,5 mm inner diameter and 1,5mm thickness, so outer diameter is 20,5mm. Material must be viton/FKM.
However, changing o-rings did not solved my high pressure fuel pump issue. Any other ideas?
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This doesnt add up?
 
I resume this topic, because for a few weeks now I have had two new errors in the engine fault memory, 16684 and 16687. the hp pump of my A2 seems to be working for the moment, but I think that sooner or later it could wear out. I saw that hp pumps are very rare and cost at least 1500 euros, is it likely to try to repair it like Jack did? I don't understand how he managed to remove the 3 tappets, which tool do you use?
 
Gorevolution said:
I resume this topic, because for a few weeks now I have had two new errors in the engine fault memory, 16684 and 16687. the hp pump of my A2 seems to be working for the moment, but I think that sooner or later it could wear out. I saw that hp pumps are very rare and cost at least 1500 euros, is it likely to try to repair it like Jack did? I don't understand how he managed to remove the 3 tappets, which tool do you use?
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I have purchased this, when my new o-rings arrive I will try swap them out.

I think the only problem some people are running into is the force required to remove them. I have also purchased some freezing spray to try add some movement.

It's a pin wrench that is supposed to be used as far as I know, others have made their own tool where a pin wrench has failed.
 

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Hi folks,

I managed to change all the O-Ring seals and here is how I did it!

First thing, the purchased Pin Wrench above was never going to work. Not strong enough and wasn't a great fit.

Tried grinding a standard socket down with two protruding pins but it broke. On hunting down an Impact Socket to try again with a stronger metal (couldn't find one on short notice) I came across a Pry Bar which had the correct dimensions on the end of it. Purchased from Halfords.

It stuck into the pin slots on the HPFP and with a Wrench, got the little parts to come loose. You will find that as soon as you get some movement they come off very easily. Then using some pliers to pull out the second part. Note - I had the HPFP in a vice and couldn't really see this thing unscrewing without one.

You will see in the pictures some dirt that was washed off with more Petrol.

I scored the metal so that when putting everything back together it was all in the same position.

So far the results have been promising, my car was bogging down just after starting the engine and stalling. Something that started happening after switching over to the Pro Boost ECU. This was believed to be happening as the Pro Boost is using more fuel at lower revs. It did happen on the original ECU but not enough that the car would actually stall. I could always just add some throttle to get past the bogging down but so far I am not needing to anymore.

See the pictures attached and I hope this helps anyone else trying to do the same.
 

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Good effort, and thanks for sharing.
A lot of members are running with proboost ECU including myself, I be surprised if the Proboost could cause this, or could it be ware & tear.
I use proboost in conjunction with Tesco momentum, have had no problem so far, but have kept a few FSI parts for a rainy day ;) .
 
Hey I found my oil refill hose has broken again. The garage that fixed it before did a terrible job by the looks of it. This is more likely the bogging down issue cause.
 
Hi all, does anyone know what the fuel pump pressure should be running at, CRGWAL above is showing his pump running at 90+ bar, i checked mine on 23/01/24 and it is showing 59.5 (spec) and 60.2 bar (actual).
Does this look too low as i am having problems with my car.
any help would be greatly appreciated folks.
 

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999fire said:
Hi all, does anyone know what the fuel pump pressure should be running at, CRGWAL above is showing his pump running at 90+ bar, i checked mine on 23/01/24 and it is showing 59.5 (spec) and 60.2 bar (actual).
Does this look too low as i am having problems with my car.
any help would be greatly appreciated folks.
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Good Evening,

No not low, your values are normal for an engine running at idle. Higher values come with higher revs.

What is the problem with your car? Maybe open a new thread (avoids thread swerve) and post an AutoScan in post 1.

Andy
 
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