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
APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”;
Version 1.0, Released 02/04/08
not be removed or altered in any way. If a fitting change must occur, this will
require you to remove the fuel inlet fitting from both your OEM supplied pump
and your APR FSI Fuel Pump and install the OEM supplied inlet fitting into
your APR pump in place of the fitting supplied by APR. Removal of each of
these fittings should be done with care such that the minimum torque is
applied with the proper tool to effect the removal and reinstallation of the
fitting.
5.1. There are two types of fuel inlet fittings that VW/Audi uses for the high-
pressure FSI fuel pump (see figures 1 and 2):
FIG 1: FSI Fuel Pump shown with Banjo type
fuel inlet fitting that is secured and sealed with a
factory banjo fitting (already on vehicle fuel line)
and a banjo-style bolt.
Banjo style fuel inlet fitting
APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”;
Version 1.0, Released 02/04/08
5.2. If you are purchasing a new (not a rebuilt) APR FSI Fuel pump, you will
receive the pump with the “Bamboo” type barbed fitting. You will need to
check the type of fitting that your vehicle was originally equipped with to
determine whether or not your original fuel line is compatible with the
Bamboo fitting. If your vehicle is directly compatible with the Bamboo
fitting, you can install your APR FSI fuel pump without the need to remove
and/or reinstall any of the fittings on the pump
5.3. If there is a need to change the fuel inlet fitting on your APR pump, this
can be done given basic hand tools including: a 14mm socket or wrench
(Bamboo fitting), a 17mm socket or wrench (Banjo fitting), a calibrated
torque wrench, and a bench-top vise (for holding the pump in place while
performing work)
5.4. You should install a clean, debris-free fitting into the APR pump and
torque the fitting to 28Nm. Note: this is the tightening torque for the
assembly of the Banjo or Bamboo-style fuel fitting into the pump only and
FIG 2: FSI Fuel Pump shown with “Bamboo”
type fitting where a hose is pushed-on to the
barbed fitting and secured with a hose clamp.
“Bamboo” style fuel inlet
fitting
APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”;
Version 1.0, Released 02/04/08
not the tightening torque for the banjo bolt that joins the fuel line to the
pump if the banjo style fitting is being used.
6. Other than the removal and reinstallation of the fuel inlet fitting (as described
in Note 5), the OEM Pressure Sensor, and the OEM Pressure Relief Valve
(Schrader valve), DO NOT disassemble any parts of the APR FSI Fuel Pump.
For information concerning the removal and reinstallation of the OEM
Pressure Sensor or the OEM Pressure Relieve Valve, please consult a
factory-authorized manual (i.e. Bentley Manual).
INSTALLATION OF APR PUMP
1) With the engine cool, disconnect the negative terminal on the battery.
2) Remove the air duct to the factory airbox, and disconnect the MAF sensor
wiring harness. Lift up and remove the factory airbox.
3) Disconnect the two electrical connectors from the top and side of the stock
FSI fuel pump.
4) If equipped, remove the plastic cap from the Schrader-style fuel pressure
release valve on the stock FSI fuel pump. Place a rag under the FSI fuel
pump and depress the Schrader valve to release any additional fuel
pressure.
5) If equipped, remove the pressure release valve from the FSI fuel pump,
being careful not to strip the fitting.
6) Disconnect the two fuel lines from the bottom of the FSI fuel pump.
7) Remove the three bolts holding the FSI fuel pump to the cylinder head and
carefully remove the pump.
8) If necessary, swap the fittings from your stock fuel pump to the APR FSI
fuel pump. See the “NOTES/RECOMMENDATIONS/PRECAUTIONS”
section above regarding the fittings on the fuel pump.
9) Swap the low fuel pressure sensor from the stock FSI fuel pump to the
APR FSI pump and tighten to 15Nm.
10) Remove the cam follower and inspect as according to the factory TSB
regarding cam and cam follower wear. If you are unsure or unable to
determine as to whether the wear on your cam follower/cam are
excessive, please contact APR or seek a second opinion before
proceeding.
11) After determining that wear is not an issue, reinstall the cam follower. If
you are using a new cam follower, be sure to use some moly grease on
the camshaft side of the follower for initial break in.
12) Lubricate the o-ring on the outside body of the APR FSI pump with engine
oil.
13) Carefully install the APR FSI pump in the cylinder head and hand tighten
the three bolts.
APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”;
Version 1.0, Released 02/04/08
14) Reinstall the fuel lines to the bottom of the APR FSI pump.
15) Torque the three bolts holding the APR FSI pump to the head to 10Nm.
Tighten the union nut on the fuel line to 25Nm. If equipped, tighten the
banjo bolt to 17Nm. If your car has a bamboo style fitting, reinstall the
hose clamp on the fitting.
16) Reconnect the two electrical connectors to the APR FSI pump.
17) Reinstall the factory airbox, the air duct to the factory airbox, and the MAF
sensor wiring harness.
18) Reconnect the negative battery terminal.
ROUTINE FUEL PUMP INSPECTION
On a periodic basis, around every ten thousand (10,000) miles, APR
recommends that you inspect the FSI fuel pump, cam follower, and camshaft in
accordance with the factory TSB for abnormal wear. If any wear appears to have
worn through the black wear coating on the cam follower, we recommend that
you replace the cam follower. Once this black coating is worn off, the wear rate
of the cam follower and lobe is dramatically increased. Keeping a good cam
follower in the car is critical to the long term operation of your vehicle.
The cam follower and camshaft wear rates on even stock vehicles appears to be
increased over what even VW/Audi has anticipated. We predict that VW/Audi will
either supersede these components to increase their longevity or they will begin
to include this inspection as a part of the routine maintenance of the vehicle.
We also highly recommend on any modified car an increased oil service interval.
Be sure to use oil that is VW 502 00 specification approved, and change the oil
on a regular basis, preferably every three to five thousand (3000-5000) miles.
If you have any questions or concerns about the installation of your APR FSI
Fuel pump, please contact APR Technical support at (800)680-7921 or (334)502-
5181. An electronic copy of this document is available on the Customer Support
section of APR’s website, www.goapr.com.
