Mike@VAST

just a picture walkthrough for the disassembly so you have a reference in case you ever decide to upgrade the internals of the FSI fuel pump. This was done on our 2006 2.0T Avant R&D car.

<b>
The Autotech fuel pump upgrade. The plunger and bore and titanium retainer with steel cotters.

<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_1.JPG">

Stock bore diameter.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_2.JPG">

Autotech bore diameter, 1.82mm larger than stock
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_3.JPG">

Unclip/unscrew everything circled here.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_4.JPG">

Relieve fuel pressure either by running the car with the fuel pump fuse removed or crack the fuel feed connection with 17mm and 14mm wrenches. Cover with a rag as you release pressure, be careful. Try to not twist the 14mm side.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_5.JPG">

Remove water pipe bracket from middle of intake manifold with T30 torx.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_6.JPG">

Remove water pipe bracket from intake manifold, above alternator, with T30 torx.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_7.JPG">

Remove fuel outlet compression fitting, 17mm wrench. Go slow at first, cover with rag for safety.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_8.JPG">

Remove two tamper proof T25 torx screws. Note the orientation of the internals and remove as well, with a magnet. Be sure to not contaminate the inside.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_9.JPG">

Remove 3 T30 screws from fuel pump housing-head. The fuel pump sits on the head with an o-ring seal and the plunger assembly with spring rides within a sleeve located in the head. Clean out the area of the head where the pump housing seated after pump removal.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_10.JPG">

Tight fit here, but remove the 14mm compression fitting for fuel. Reinstalling is a pain as well. Be sure to start the fitting on the threads by hand before you start tightening with the wrench.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_11.JPG">


I didn't have the correct 12 point socket for this, but, a T25 torx bit will remove it. I replaced this goofy bolt with a standard 10mm head/M6x10mm bolt.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_12.JPG">

Removal of the last fuel fitting on the bottom of the pump housing, it's a 6mm triple square. I put a 13mm wrench on the triple square bit and squeezed my way into the area and removed the compression fitting banjo bolt. It's not easy, just take your time and try not to bend anything in the area too far. Reinstalling is just as difficult, get it started by hand first.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_13.JPG">

Put the fuel pump in a vise, not too tight, don't drop it! Pull straight up on the spring/plunger assembly and it will come right out.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_14.JPG">

Remove the guide/seal with a CLEAN(internally as well) 18mm deep socket(CLEAN YOUR TOOLS PRIOR TO WORKING ON THE PUMP)
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_15.JPG">

The plunger guide/concentric seal.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_16.JPG">

The plunger guide/bore. Note the orientation.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_17.JPG">

Remove the relief valve, 32mm wrench!
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_18.JPG">

Closeup of the relief valve.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_19.JPG">

Remove and note the orientation of this 3 piece assembly. It's ok if it comes apart, just be sure to put it back together the same way it came apart.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_20.JPG">

Use the closed end of a 17mm wrench to remove this fuel compression fitting. There will be a crush gasket below it, note its orientation as well and remove it.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_21.JPG">

Again, use the closed end of a 17mm wrench to remove this fuel compression fitting. There will be a crush gasket below it, note its orientation as well and remove it.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_22.JPG">

All of the removed parts, according to Autotech, they wanted all of this removed and cleaned before reinstallation, and clean the pump housing as well and blow it all out with compressed air. Make sure everything is free of dirt and debris before reinstallation.
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_23.JPG">

Installation of the new plunger assembly. Note the orientation of the bore/collar, the small side points down. You can dip both in gasoline and reinstall. Lube the concentric seal that goes around the plunger with a dab or two of oil as well. Once this is sitting in the pump housing, put the clean spring over the plunger then put the titanium retainer down on the spring, push down, then install the two halves of the cotter(retainer that looks the same as valve guide retainers in cylinder heads). So that's about it! Just lube all the o-rings with a dab of oil and make sure everything goes in straight and cleanly. Good luck
<img src="http://www.vastperformance.com/images/2.0T_FSI/autotech_fp_install_24.JPG"></b>

addìct

great write-up. this should go in the tech articles.

g_svan

Great job Piggie! I'll definitely use this walkthrough when it's my turn

Ed@mtl

Great DIY.

Aarononymous

nice Facom ratchets, love those things

Mike@VAST

had some problems with the adjustment in them.

Tgr_Clw

Awesome write up.

maaliish

Great writeup!

Aarononymous

or at least the toothed part. I used to see Facom rebuild kits on ebay but are probably impossible to find now<ul><li><a href="http://SK%20rebuild%20kits%20hear">http://www.thetoolwarehouse.net/shop/SK-42475-2.html</a></li></ul>