APR FSI Fuel Pump Installation Fsi_fuelpump_installation Fuelpump

User Manual: fsi_fuelpump_installation

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  APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”; Version 1.0, Released 02/04/08 APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions  PREFACE The installation of the APR FSI Fuel Pump onto any VAG 2.0T FSI engine should be carried out using all of the factory recommended installation procedures and precautions.  The notes, recommendations, and precautions in this document are intended as a supplement to those already provided by VAG.  This entire document must be read and understood before attempting to install your APR FSI Fuel pump.  WARNING: Direct Injection FSI fueling systems run at very high pressures.  The pressure in the fuel lines must be relieved prior to removal of the fuel pump to prevent serious bodily injury.  Please consult a factory-approved repair manual (i.e. Bentley manual) for the proper procedures and precautions.    INSPECTING YOUR VEHICLE BEFORE INSTALLING THE APR FSI PUMP To ensure that your vehicle is ready for the installation of the APR FSI pump, you must be aware of the condition of the mechanical components that drive the pump in your 2.0T FSI equipped vehicle.  This is critical to the operation and longevity of your vehicle and your APR FSI Fuel Pump.    The high-pressure FSI fuel pump used in the 2.0T FSI equipped vehicles is mechanically driven by the intake camshaft and is therefore directly tied to the vehicle valve train assembly.  In addition, there is a low-pressure feed pump at the fuel tank of your vehicle and a fuel filter with integral pressure-regulator that are important to the operation of the APR FSI pump.  To add to the complexity, there are many auxiliary sensors and pressure relief valves that are all critical to the proper operation of the direct injection fueling system on your vehicle.  It is the responsibility of the customer and/or the installer to ensure that all the vehicle components driving the FSI fuel pump are in good working order and are not in a state of excessive wear or failure prior to the installation of the APR pump.    Volkswagen of America, Inc. has released a Technical Service Bulletin (TSB) stating that there is a known problem concerning premature wear of the intake camshaft lobe and camshaft follower that drive the FSI high-pressure fuel pump. This wear has been known to cause fuel delivery issues and fuel rail pressure fluctuations.  If this wear goes unchecked, wear can also begin on the base of the FSI high-pressure fuel pump.  In some cases, this wear can result in a complete failure of the intake camshaft which may result in extensive damage to the engine valve train, head, and other related components.  The published TSB describes the proper method for inspecting your vehicle for this type of wear and
  APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”; Version 1.0, Released 02/04/08 also describes what steps should be taken to repair the damage through your factory-authorized service department.  Please go to the internet link below to view a copy of the VW/Audi Technical Service Bulletin related to premature cam lobe wear:  http://www.goapr.com/images/support/tsb/20t_cam_wear.pdf  IT IS THE RESPONSIBILITY OF THE END-USER TO ENSURE THAT THE FUEL PUMP RELATED CAM LOBE, CAM FOLLOWER, AND ORIGINAL FUEL PUMP ARE IN PROPER WORKING ORDER PRIOR TO INSTALLATION OF THE UPGRADED APR FSI FUEL PUMP.  In addition, if the vehicle has had any issues related to fuel delivery prior to the installation of the APR pump, a thorough inspection of the other components related to fuel delivery may be necessary.     NOTES/RECOMMENDATIONS/PRECAUTIONS Working with the FSI Fuel Pumps: 1.  Precautions should be taken to keep the FSI fuel pump in a clean environment free of dust, sand/grit, metal shavings, etc. prior to and during the installation process. The pump should remain in a clean plastic bag until it is ready to be fitted to the vehicle.    2.  The APR FSI Pump will be shipped with all inlet, outlet, and pressure ports covered.  These ports should remain covered until the last possible minute to ensure that there is no contamination within the pump chambers prior to installation  3.  Take care not to drop the OEM or APR FSI Pump or subject it to any impacts prior to or during the installation process  4.  Prior to installation of the OEM Pressure Sensor and/or Pressure Relieve Valve (Schrader valve) into the APR FSI Pump, make sure that the threads are clean of debris, sand/grit, and/or metal shavings, etc.  The threads of these fittings can be cleaned with a standard brake cleaner while debris can be removed with a shot of compressed air.    5.  The installation of your APR FSI Fuel Pump may require that you remove the fuel inlet fitting from your OEM supplied pump and install that fitting into your APR FSI Fuel Pump (based on part revision changes made by VW/Audi). You must check the type of fuel inlet fitting that is located on your original FSI fuel pump before starting the installation to ensure that you properly prepare your APR FSI pump for fitment on your vehicle. NOTE: the fuel outlet fitting should

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