DIY DIY - HPFP Removal and Cam Follower Replacement
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Thread: DIY - HPFP Removal and Cam Follower Replacement

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    DubMeister SpeeDemon's Avatar
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    Default DIY - HPFP Removal and Cam Follower Replacement

    Hey everyone,

    It's been a while since I last posted a new DIY (lol, that's what happens when you get married!). Anyways, I decided to go with APR's rebuild HPFP since namotorsports.com is having an APR sale that actually ends tonight (10/31/10) in honor of H2O. I didn't mind the price since it was on sale. I happily paid the extra $150 vs. AWE's (which I was looking at heavily) to have the peace-of-mind knowing that my pump was tested before and after the rebuild.

    Here's what you'll need in the way of tools/parts:
    1) OEM Cam Follower (got mine for $50 at ecstuning.com)
    2) Shop rags
    3) Protective eyewear
    4) 17mm box wrench
    5) 13mm box wrench
    6) T30 Torx
    7) M8 Triple Square
    8 )Tape
    9) Flat-head screwdriver
    10) Skoal (optional) ;-)

    Install time: 30-45min (depending on how fast you can get the M8 Triple Square nut removed)

    Process:

    This install is pretty straightforward. I think the main question people might have is the depressurization process...

    1) Depressurizing the HPFP. This step has a few variations to it, I liked mine because I didn't have any fuel to clean up. I started by removing the top sensor (fuel pressure regulator) on the N276. A flat-head screwdriver helps with unsnapping it. Don't remove the sensor under the PCV hose yet (sensor on left side of HPFP). If you're wondering what that green square is to the bottom right of the HPFP, some newer model GTI's have a bleeder valve.


    - Start the car and let it run for about 10 seconds. You'll hear a bit of sputtering going on. Don't worry, it's normal.

    - Next, remove the HPFP Fuse (blue 15amp) from side panel on driver's side dash.


    - Start the car again. It will only continuously turn at this point. Do this for 5 seconds.
    At this point, your HPFP's pressure will have gone from 100bar to about 3bar.

    2) Assuming you have already removed the engine cover/air intake, remove the second sensor on the left side of the HPFP. Also, if your pump has a bleeder valve, put on protective eyewear and unscrew it using (I believe) a 17mm or 13mm box wrench.


    3) For clearance purposes, remove the hose fitting below the main PCV hose. This fitting has to be unsnapped from all 4 corners in order to release. Using a flat-head screwdriver helps. Some have suggested removing the main PCV hose and Boost tap line, you do NOT need to do this (there's enough clearance to work with).


    4) Slide a shop rag underneath the HPFP.

    5) Use the 17mm box wrench to remove the sleeve on the 1st fuel line (to the right, circled in red).



    4) I used some tape around my M8 Triple Square bit to hold it in place with a 13mm box wrench. Because my M8 bit was too long, I ended up just holding the bit in place with my hand and using the 13mm box wrench to loosen it. If you have a smaller M8 bit, the tape idea will work.

    This was the best angle for leverage with my wrench:


    5) At this point, all that's left is to remove the three T30 Torx bolts holding the HPFP to the engine.


    6) Slide your finger into the hole and pull out the Cam Follower.


    7) Replace with the new Cam Follower.


    8 ) And you're done. Simply put everything back together in reverse order.

    Here's a pic of the old and new Follower. Mine didn't really need to be replaced yet, but since I was sending my HPFP to APR, I figured I'd go ahead and replace it. Not too much wear showing yet.


    Enjoy,

    SD

    P.S. The torque specs for the bolts are:

    T30 Torx bolts: 10Nm
    Banjo Bolt: 17Nm
    Fuel Line Nut: 25Nm
    Last edited by SpeeDemon; 11-18-2010 at 08:33 AM. Reason: Torque specs for bolts
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    firstly, thank you a ton for doing this. second...when/why should this get replaced? are there symptoms? precautionary? i hear everyone SWEAR against these things...what do they DO?

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by ronin666 View Post
    firstly, thank you a ton for doing this. second...when/why should this get replaced? are there symptoms? precautionary? i hear everyone SWEAR against these things...what do they DO?
    http://www.ecstuning.com/Search/Cam_Follower/ES252809/

    when i had my mk5 i checkd it every other oil change and replaced it if it got looking to worn down ......this is what WILL happen if u dont stay on top of it





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    Quote Originally Posted by ronin666 View Post
    firstly, thank you a ton for doing this. second...when/why should this get replaced? are there symptoms? precautionary? i hear everyone SWEAR against these things...what do they DO?
    It will cause you fuel to cut out and it can also damage othe fuel pump the cam sits on the loab of your cam and if it is sevely damaged the fuel pump.part will.hit the loab.

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    roflwaffle #tehawareness

    by every other oil change,were talkin 20k miles?



    -thanks again x2

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by ronin666 View Post
    roflwaffle #tehawareness

    by every other oil change,were talkin 20k miles?

    -thanks again x2

    No by every other oil change i meant 10k .... I changed mine like ur supposed to not the 10k between service changes that the vw owners manual says .... The only oil i trusted to go that far was the amsoil i was running for the last 20k of her life
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by Teh Chr!s View Post
    No by every other oil change i meant 10k .... I changed mine like ur supposed to not the 10k between service changes that the vw owners manual says .... The only oil i trusted to go that far was the amsoil i was running for the last 20k of her life
    But be careful as no amsoil is 502 certified..
    Sometimes it seems that people take the cam follower situation to far and replace every 10K. I don't recommend that at all.
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by Voyles View Post
    But be careful as no amsoil is 502 certified..
    Sometimes it seems that people take the cam follower situation to far and replace every 10K. I don't recommend that at all.
    if u notice in my other post john i said i would check it every other and then replace it if needed
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by Teh Chr!s View Post
    if u notice in my other post john i said i would check it every other and then replace it if needed
    gottcha
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    so this cam follower thing, i have 40k+ miles on my mkv right now, ive been having issues when accelerating at highway speeds, as i hit the gas i get this "thump" and it kinda shakes the whole car. could that be the cause of a cam follower being to worn? i have no idea if the previous owner replaced it in the time they had it.

    so could it cause fuel cuts or that sudden shudder on the highway?
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by The_Unnamed_ View Post
    so this cam follower thing, i have 40k+ miles on my mkv right now, ive been having issues when accelerating at highway speeds, as i hit the gas i get this "thump" and it kinda shakes the whole car. could that be the cause of a cam follower being to worn? i have no idea if the previous owner replaced it in the time they had it.

    so could it cause fuel cuts or that sudden shudder on the highway?
    yes, your HPFP/cam follower can cause fuel cuts
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    And just the fuel cut could cause that shudder? kinda feels like running over a manhole cover, just a quick bump and then its gone
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by The_Unnamed_ View Post
    And just the fuel cut could cause that shudder? kinda feels like running over a manhole cover, just a quick bump and then its gone
    I hate to say it but that almost sounds like a tranny issue
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    Quote Originally Posted by SpeeDemon View Post
    I hate to say it but that almost sounds like a tranny issue
    I would look into that also. But with the mkv the subframe bolts come loose. I found out the hard ways. My thumping went away with the subframe spacers last night.



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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    well neither of those sound good.. lol warranty isn't up yet, should i bring it in and have them check the trans?

    it doesnt do the thump all the time, or in every gear. its pretty random. and never does it when i first shift into the gear. Only after its in gear already and im accelerating a bit, very strange.
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    Quote Originally Posted by The_Unnamed_ View Post
    well neither of those sound good.. lol warranty isn't up yet, should i bring it in and have them check the trans?

    it doesnt do the thump all the time, or in every gear. its pretty random. and never does it when i first shift into the gear. Only after its in gear already and im accelerating a bit, very strange.
    If it is under warrenty i would take it in. Also check out your dog bog mount.
    Warrenty is your best friend with a newer car.

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by fastgti View Post
    If it is under warrenty i would take it in. Also check out your dog bog mount.
    Warrenty is your best friend with a newer car.

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    will do, thanks for the help
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by The_Unnamed_ View Post
    so this cam follower thing, i have 40k+ miles on my mkv right now, ive been having issues when accelerating at highway speeds, as i hit the gas i get this "thump" and it kinda shakes the whole car. could that be the cause of a cam follower being to worn? i have no idea if the previous owner replaced it in the time they had it.

    so could it cause fuel cuts or that sudden shudder on the highway?

    I'm having this same problem. Especially in 4th gear accelerating hard. I'm stage 2 and haven replaced my cam follower. If you could tell me what the dealership says I'd appreciate it. No warranty for me. ):

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by VWGTIWV View Post
    I'm having this same problem. Especially in 4th gear accelerating hard. I'm stage 2 and haven replaced my cam follower. If you could tell me what the dealership says I'd appreciate it. No warranty for me. ):
    no prob, havent gotten time for it yet, guna set an appointment up after im done with school and the holidays
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    So I decided to order a cam follower for my car. Just in case it needed to be replaced, i didn't want to be stuck without one. So it turns out that it didn't need to be replaced. At least I don't think it needs to be replaced.......you guys be the judge
    Click image for larger version.

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    Couple.scratches I would its a cheap enough part.

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Whats the advantage of replacing it over a couple of scratches?

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by latintiger View Post
    Whats the advantage of replacing it over a couple of scratches?
    its new...... serious question ?
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    yes, serious question.
    why would scratches affect it's use?
    Im not trying to be a jerk about it, just doesn't make sense to replace it over scratches.

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    its thin.... as scratches occur its shaving down the metal.... then eventually looks like this

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Gotcha. Thanks.
    Any idea what causes that type of damage?

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    ****ty motor design by vw.

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    Quote Originally Posted by latintiger View Post
    Gotcha. Thanks.
    Any idea what causes that type of damage?
    Low oil, and it naturally destroys itself anyway due to a design flaw

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Hi All,

    I signed up to this thread just to share what I know, to help in sharing of information. I'm from Australia and own an Audi DTM A4 edition with the 2.0 FSI engine.

    I checked my follower at around 60,000 klms (40,000 miles) about two years ago when I first read about this issue. I thought I would find a damaged follower but I was surprised that mine was basically, still in good reasonably good condition. Although the Teflon coating has rubbed off in places, the follower still had a flat surface and as you can see, my cam looks like it is still in perfect condition with a very smooth surface.

    http://www.ozaudi.com/photopost/show...resize&cat=631

    Using the photo above that shows a severly damaged follower at 50k miles as a reference, you can see the amount of wear is completely different than mine at around 40k miles. Even though I hadn't done 50k miles at that time, I still expected to see a pretty damaged follower (I had seen that pic of the various damaged followers at that time).

    Although I had no reason to change my follower at that time, I wanted to understand why mine had not shown the wear that I had read about on the internet. My research led me to believe this is actually caused by the oil that you are using there in the States, and more importantly the oil composition and ZDDP content. I think from memory I read and believe this problem to be caused by the regulations in the states about oil composition and subsequent decrease in ZDDP content in your oils. If you feel like it, you can do a google search for "Cam follower ZDDP" and find plenty of information to keep you occupied for a while.

    I am now about to come up on my 90 klms service, and am going to change the follower as part of a regular maintenance routine. I'll post a pic of mine after 90k if it interests anyone.

    Don't get me wrong, I still believe that every owner should be well aware of this issue and this should be a regular maintenance item (inspection only, replace if necessary) for all Audi/VW owners. I just want to help clarify that this problem isn't correctly explained as a design issue or oil supply problem.

    For your information I use Castrol (BP) Edge Sport (0-40) in my car at every oil change, which I believe (at least here in Aus) has a good ZDDP content and is the reason why this is so much less of a problem here..

    Hope this helps..
    Steve
    Last edited by Rogue; 03-22-2012 at 12:02 AM.

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    It also depends if someone is running s stage 2 plus tune. Which wares it a lot faster

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by Rogue View Post
    Hi All,

    I signed up to this thread just to share what I know, to help in sharing of information. I'm from Australia and own an Audi DTM A4 edition with the 2.0 FSI engine.

    I checked my follower at around 60,000 klms (40,000 miles) about two years ago when I first read about this issue. I thought I would find a damaged follower but I was surprised that mine was basically, still in good reasonably good condition. Although the Teflon coating has rubbed off in places, the follower still had a flat surface and as you can see, my cam looks like it is still in perfect condition with a very smooth surface.

    http://www.ozaudi.com/photopost/show...resize&cat=631

    Using the photo above that shows a severly damaged follower at 50k miles as a reference, you can see the amount of wear is completely different than mine at around 40k miles. Even though I hadn't done 50k miles at that time, I still expected to see a pretty damaged follower (I had seen that pic of the various damaged followers at that time).

    Although I had no reason to change my follower at that time, I wanted to understand why mine had not shown the wear that I had read about on the internet. My research led me to believe this is actually caused by the oil that you are using there in the States, and more importantly the oil composition and ZDDP content. I think from memory I read and believe this problem to be caused by the regulations in the states about oil composition and subsequent decrease in ZDDP content in your oils. If you feel like it, you can do a google search for "Cam follower ZDDP" and find plenty of information to keep you occupied for a while.

    I am now about to come up on my 90 klms service, and am going to change the follower as part of a regular maintenance routine. I'll post a pic of mine after 90k if it interests anyone.

    Don't get me wrong, I still believe that every owner should be well aware of this issue and this should be a regular maintenance item (inspection only, replace if necessary) for all Audi/VW owners. I just want to help clarify that this problem isn't correctly explained as a design issue or oil supply problem.

    For your information I use Castrol (BP) Edge Sport (0-40) in my car at every oil change, which I believe (at least here in Aus) has a good ZDDP content and is the reason why this is so much less of a problem here..

    Hope this helps..
    Steve
    That is good information but when I pulled my follower out at 40k then it showed about the same amount of wear as yours did.


    It may have something to do with the specs of the oil we have here in the states but it also has to do with the design of the follower itself, cam lobe, and if people do not keep up on checking their oil and making sure that there is an adequate amount to "lube" the follower and the cam shaft then it starts to eat itself due to friction. Lubrication is key... I believe that is a quote.
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    Its like the girl that had chlamydia last year, hitting you up and wanting to go out. You know it was taken care of a while back, but you still don't know if your trust it

    Hidden Content Originally Posted by csmith1957 Hidden Content
    It was all xcrazydx's hard work. He got all up in my hatch

  34. #32
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    That's what she said.

    Im prob going to replace mine this weekend. I'll post for reference. I can't believe how bad that one in the photo is after just 15k miles.. crazy. Almost looks like there was no lubrication at all.

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by Rogue View Post
    That's what she said.

    Im prob going to replace mine this weekend. I'll post for reference. I can't believe how bad that one in the photo is after just 15k miles.. crazy. Almost looks like there was no lubrication at all.
    Well if it was the A revision cam then I am not surprised at all. Poorly designed piece and it did not help the wear at all. We both have the B revision came so it doesn't wear as fast and actually "rolls" over the cam more evenly and decreases wear, as long as you keep oil in there.

    Oh, nice car by the way. Post some pics up somewhere and what you have done.
    2008 GTI with lots of stuff. Hidden Content
    Hidden Content Originally Posted by dman624 Hidden Content
    Its like the girl that had chlamydia last year, hitting you up and wanting to go out. You know it was taken care of a while back, but you still don't know if your trust it

    Hidden Content Originally Posted by csmith1957 Hidden Content
    It was all xcrazydx's hard work. He got all up in my hatch

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    Default

    Quote Originally Posted by MiniCoopKiller View Post
    That is good information but when I pulled my follower out at 40k then it showed about the same amount of wear as yours did.


    It may have something to do with the specs of the oil we have here in the states but it also has to do with the design of the follower itself, cam lobe, and if people do not keep up on checking their oil and making sure that there is an adequate amount to "lube" the follower and the cam shaft then it starts to eat itself due to friction. Lubrication is key... I believe that is a quote.
    It is a design issue, that's why they extended everyones warranty and did away with the design for the next model.

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    Hidden Content Originally Posted by volcano Hidden Content
    well im a blob and im comfortable in my mk4
    Hidden Content Originally Posted by D.Light
    I LOVE GTI"S AND MMA AND I SMOKE CRACK LOTS AND LOTS OF CRACCCCKKKKKKKKKKK NEEEGGGGGRRROOOOOOOOOEESSSSS
    Hidden Content Originally Posted by csmith1957
    Bang bang tang!!

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by MiniCoopKiller View Post
    Well if it was the A revision cam then I am not surprised at all. Poorly designed piece and it did not help the wear at all. We both have the B revision came so it doesn't wear as fast and actually "rolls" over the cam more evenly and decreases wear, as long as you keep oil in there.

    Oh, nice car by the way. Post some pics up somewhere and what you have done.
    Thanks for the comment mate. If you want to see a few more pics of my A4 DTM look here:
    http://www.ozaudi.com/photopost/showgallery.php?cat=633

    I changed over my follower last night. There is a definite degradation from 60k, but the surface on my follower is still extremely smooth to the touch so it probably still had some go in it even at 87k klms. It makes you wonder why there is such a difference, so I just cant accept "bad design" - a bad design would have this catastrophic failure across the entire production.

    In any case, its something to stay on top of. The pictures of my 90k replacement are here:
    http://www.ozaudi.com/photopost/showgallery.php?cat=632

    Cheers, Steve

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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Sweet! gonna do this soon with 131k.
    2007 Volkswagen GTI DSG|Boost Gauge|Vogtland Springs|Sunroof
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Love this thread & DIY, just used it last night to finally replace my Cam Follower. I've been bad (mostly from ignorance) and I drove 70+ miles without checking it and I have no idea if the previous owner ever did.

    Good thing I did because I basically pulled out pieces of what used to be a cam follower.

    My question is this: Is there ANY trick out there as to accessing that "banjo bolt" easier? I did what was shown here with the M8, 1/2" box wrench and tape, but there was just no wiggle room. Getting it back on took 20 minutes itself! This was a 2 hour job for me, mainly because I'm a newbie still and this was my first time taking the HPFP off.
    Based on what I went through last night, I have NO desire to go back in there myself but I hate paying people to work on my car.

    Tricks? fixes? beer? mild sedative? is anyone listening to me?

    thanks!

  40. #38
    DubMeister SpeeDemon's Avatar
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Quote Originally Posted by seanpryan87 View Post
    Love this thread & DIY, just used it last night to finally replace my Cam Follower. I've been bad (mostly from ignorance) and I drove 70+ miles without checking it and I have no idea if the previous owner ever did.

    Good thing I did because I basically pulled out pieces of what used to be a cam follower.

    My question is this: Is there ANY trick out there as to accessing that "banjo bolt" easier? I did what was shown here with the M8, 1/2" box wrench and tape, but there was just no wiggle room. Getting it back on took 20 minutes itself! This was a 2 hour job for me, mainly because I'm a newbie still and this was my first time taking the HPFP off.
    Based on what I went through last night, I have NO desire to go back in there myself but I hate paying people to work on my car.

    Tricks? fixes? beer? mild sedative? is anyone listening to me?

    thanks!
    Glad this helped. You could try a flex ratcheting wrench like these craftsmans:
    http://www.sears.com/craftsman-cm-wr...7&blockType=G7

    I just made due with what I had. I wasn't willing to buy another tool just to make my job go about 10 minutes faster. I'm cheap when it comes to stuff like that.
    REVO Stage 3, K04 w/Forge Wastegate, RS4 Injectors, R8 Pressure Regulating Valve, APR Pump, EVOMS CAI, Milltek Exhaust, Synapse DV, BSH Throttle Pipe, S3 Diffuser Pipe, Forge Intercooler, 42DD Stealth Catch Can, NewSouth Boost gauge, Dieselgeeks Short shifter, Clubsport suspension, RSD rear stress bar, H&R F&R sway bars, tint, grounds

  41. #39
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    ooh, I like those. Steep price. I'm a sucker for gadgets and tools, I may have to purchase

    Quote Originally Posted by SpeeDemon View Post
    Glad this helped. You could try a flex ratcheting wrench like these craftsmans:
    http://www.sears.com/craftsman-cm-wr...7&blockType=G7

    I just made due with what I had. I wasn't willing to buy another tool just to make my job go about 10 minutes faster. I'm cheap when it comes to stuff like that.

  42. #40
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    Default Re: DIY - HPFP Removal and Cam Follower Replacement

    Thanks for the DIY, I did my first one at 100,200 miles on my 2008 Jetta GLI/FSI. I was surprised to to see minimal wear after hearing/seeing all the horror stories on the forums. I don't have a computer flash and only take spirited drives occasionally, which may have contributed to the good wear. Click image for larger version.

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