A special thanks to Hitachi Automotive Systems Espelkamp GmbH for their help with this particular issue -


High Pressure Fuel Pump EASY Replacement on TFSI Engine
www.youtube.com/watch?v=m_8G0Ek7QmU

You're wondering how to properly replace a high pressure fuel pump on a gasoline engine? Then you have come to the right place. We'll show you how to detect a faulty air flow sensor, check the part correctly and, in the event of damage, remove and reinstall it properly.

This video serves to avoid mistakes when changing the sensor and to save you from a faulty purchase.

(This video also includes removal, inspection and replacement of the cam follower)

Here's some additional information from Hitachi Automotive Systems Espelkamp GmbH with some specific Questions and Answers regarding the HPFP. A very special thank you to Slava Merk and Patrick Freier from HÜCO and their outstanding customer support and willingness to help! [smiley=thumbsup.gif]

Q1.) After the fuel pump is replaced, is an OBD (VAGCOM) Basic Setting required? It wasn't mentioned in either of the videos, however it is mentioned in the Ross-Tech website linked below.

A1.) For vehicles with TFSI engine with timing belt, the following requirements shall apply after the fuel feed unit has been replaced, it is connected to the engine control unit. For vehicles with a TFSI engine with timing chain drive, this is not required. We had a vehicle with chain, so we added a comment under the video.

Q2.) Does HÜCO offer fuel pump repair kit to replace the plunger end-cap fitted on the end of the spring. In some cases, I've seen where the cam follower is quite worn and wondering it would be possible to replace just the cam follower and plunger end components rather then the entire fuel pump?

A2.) Unfortunately we cannot offer repair kits for safety reasons. Here is an example of a "repair kit":

If the pump fails, there is also a high risk that metal particles or other contaminants will be deposited inside the internal fine filter, so we always recommend to replace the pump completely.

Q3.) With respect to the cam follower, can you provide a dimension by which it could be measured to determine the level of wear? A simple measurement would be helpful to determine how much wear has occurred to the cam follower and if it's still okay to use or not.

A3.) You will find the customer drawing in the attachment. I would also advise you to make sure that the protective coating is also intact as soon as it is rubbed off, which increases the risk of damage many times higher.


Q4.) As you may be aware, Audi does not mention the cam follower as part of the scheduled maintenance program. However it's quite obvious this should be done routinely, do you have any recommendation for how frequently this should be done? Every 10, 15 or 25,000km?

A4.) Yes you´re right, in Europe they don´t mention it, however in the US there is a service bulletin. (15 07 02 June 18, 2007 2013147/4 . Supersedes Technical Bulletin Group 21 number 06-04 dated Dec. 11, 2006 due addition of description of one of the main condition that can result in the storage of P2293. (See PDF download below)

The normal tappets should be tested 30,000-40,000 km. Depending on the driver and driving style you can't say for sure. Also important is the right and fresh oil.

Q5.) Does HÜCO offer a replacement PHFP for the Audi TT VR6, 3.2 engine? And do you have installation instructions or parts for this engine model?

A5.) To give a more accurate answer I need a reference number or a chassis number. (to be updated)


While not specified in the Audi Schedule Maintenance list, this has been a well known issue since Audi published a TSB on the fuel pump cam follower back in 2007. You can download the attachment below.

It's been quite well documented on various YouTube videos and as always, you can find how to inspect and or replace it yourself from the link below. If DIY isn't for you, at least ask for your Service Center to check it out next time it's in the shop just to make sure it's okay. The Cam Follower is item 6 in the image below -



PDF for the TSB can be downloaded here -
View attachment 6

A post on the Cam Follower inspection and replacement can be found here -
https://www.ttforum.co.uk/forum/viewtop ... &t=1879535

HP Fuel Pump Thrust Sensor -

If your getting any of the following fault codes; P0087, P1093, or P2293 the Thrust Sensor may be suspect. You may want to check yours as the old one is revision "E" and the newer version is "K" so if you have the older version, it might be time to replace it anyway. It's listed as Item #4 in the parts diagram above. The part number is 06E 906 051 K.


DIY HP Fuel Pump Cam Follower Replacement -

You can check out a discussion about the cam follow replacement from Charles the Humble Mechanic in his YouTube video on the HPFP Cam Follower linked below.

How to Inspect and Replace a FSI Cam Follower and HPFP

There's some really good information and tips so you get this job done right! As noted in the video, when you rotate the engine to get the flat of the cam in the right position, use a 19mm socket and always turn clockwise.


If your line fitment includes a banjo bolt on the fuel line, this Schwaben Stubby Socket Driver Set might come in handy.


A severely worn through cam follower can lead to major cam damage which is why this service needs to be included in your service intervals.


When turning the cam, rotate the engine in the direction shown. In this case, front is on the right side, therefore the wrench on the drive pulley is pulled towards you.