How To: Replace HPFP Cam Follower

[b8s4me]

Hello everyone! I decided to replace my cam follower today and thought why not document in case others want/need to also? I come from a B8 A4, and cam follower failure can lead to a damaged cam/motor, and their lifespan on the A4 is 30k but most people recommend changing every 10k because they're so cheap, and not replacing them can be costly.

For those who are unaware, the high pressure fuel pump creates fuel pressure off the camshaft lobe. Everytime the cam spins, it causes the hpfp spring to push in and out, creating a metric shit-ton of fuel pressure as required for direct injection. The cam follower is the mediary between the hpfp spring and the camshaft.

TOTAL TIME: 30 - 45 minutes

PARTS

You will need a new cam follower listed here (https://www.ecstuning.com/Audi-B8_S4-Quattro-3.0T/Engine/Fuel/Pump/Cam_Follower/), I went with the INA follower. Although not required, I HIGHLY recommend getting 2 brand-new bolts that hold the hpfp onto the vacuum pump. You can find them here (https://www.ecstuning.com/Audi-B8_S4-Quattro-3.0T/Engine/Fuel/Pump/), make sure you choose the right bolts for your production year!

INSTRUCTIONS


STEP 1: Locate hpfp/clear surrounding area

The high pressure fuel pump sits directly behind a black metal shield. I have a USP intake and had to remove it, you may need to as well.

http://i.imgur.com/smcrtlH.jpg



STEP 2: Remove black shielding

Get a 10mm socket and remove the 2 bolts below. The black shield will just pull right off.

http://i.imgur.com/rm4kCRf.jpg




STEP 3: Disconnect fuel lines

Use pliers to take off the black hose and hold a rag as fuel will spray, then use a 17mm wrench to loosen the bolt holding down the metal fuel line next to the black hose. Fuel will spray here too, but not as violently. Use rags/tampons/your cat etc.

http://i.imgur.com/YNeySZJ.jpg





STEP 4: Disconnect ignition coil harness/sensors
I found that this made things much easier and faster. Use a T15 to remove the 2 bolts holding the ignition coil harness to the valve cover. Disconnect the 4 sensors that run to the ignition coil harness (2 on top, 2 connected to the hpfp underneath. I didn't take pics of this step but it should be easy enough!



STEP 5: Remove hpfp bolts
Use a size 6 hex bit to remove both bolts holding the hpfp onto the vacuum pump. Once you do so, the hpfp will be loose and everything should look like the below picture.

http://i.imgur.com/LQkd0Ah.jpg



STEP 6: Remove hpfp

Pull the hpfp directly out. I had to slightly bend the metal fuel line upwards to fully release it. If you're lucky, you will catch the cam follower as it slips out. Unfortunately I didn't...

Here are pics of the hpfp removed. The pics aren't really good for anything, but I've used pics from other how-to's to cross reference other unrelated things I'm doing, so why not take them?

http://i.imgur.com/KeKgEtV.jpg
http://i.imgur.com/fyLDyCH.jpg
http://i.imgur.com/2qSCw2B.jpg
http://i.imgur.com/LzB2tfD.jpg




STEP 6: Install cam follower

Note the groove in the below picture, it is very important as you need to line up the notch on the new cam follower into it.

ALSO, VERY F****ING IMPORTANT!!!! Install the new cam follower JUST LIKE THE PIC BELOW! The "roller" side should seat INSIDE of the vacuum pump, and the spring on the hpfp should sit INSIDE the flat part of the cam follower. If you look at the 2nd pic below, that is how the cam follower is to be oriented. DO NOT MESS THIS UP!

http://i.imgur.com/UAgFmy5.jpg
http://i.imgur.com/LSf6coZ.jpg



STEP 7: Reverse install

Read all steps up until this point and reverse them. Use the new bolts (or reuse your old ones) and install the hpfp to the vacuum pump. Connect all sensors, and connect the fuel lines. It took my car about 10 seconds to fire up as there was no fuel in the lines. Once you start her up, check for any fuel leaks and tighten down anything if you do.

Random thoughts

Ever since I've owned this car, no one could tell me anything about cam follower replacement, or when it should be done. I've talked to lots of vendors at car events, and none could tell me anything. Most have never heard of a cam follower failure on the S4, although it does happen on the A4. I've put 45k miles on my car since I've owned it, and the cam follower I removed still looks useable. On an A4, I would have shit myself at the thought of a cam follower being in there that long. It is completely possible that the S4 cam follower requires no maintenance, but for my ease of mind it is replaced.

Also, if anyone is doing an AUTOTEC hpfp spring upgrade, you would follow the exact procedures here, but then disassemble the hpfp and install the new spring.

[LittleDozer]

I'm happy to see yours had the same wear marks as mine! Was worried it wasn't normal. Realistically it's not necessary on our rollers but I saw the stripes/wear on mine and replaced it as well.


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[b8s4me]

I'm happy to see yours had the same wear marks as mine! Was worried it wasn't normal. Realistically it's not necessary on our rollers but I saw the stripes/wear on mine and replaced it as well.


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I was pleasantly surprised when I saw mine. When I replaced my A4 after reading a thread on cam follower failures, I immediately did mine and it was in much worse shape. My car has 116k and who knows if it was ever replaced before I bought it at 70k.

[bhvrdr]

Thsnks for the writeup. Could you tell the service life yours may have?

Mike

[b8s4me]

Thsnks for the writeup. Could you tell the service life yours may have?

Mike

Honestly I couldn't. I've owned the car and put 45k on it without changing the cam follower, and it still looks useable. I wouldn't be surprised if it's never been changed out, til today.

[jimrobbington]

How necessary is this? I came from the B7 works where follower replacement was a must. I replaced 5 over the 75k I had it. I thought the new roller design wasn't supposed to need maintenance?

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[b8s4me]

How necessary is this? I came from the B7 works where follower replacement was a must. I replaced 5 over the 75k I had it. I thought the new roller design wasn't supposed to need maintenance?

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Same with the B8 A4, requires constant replacement. I couldn't find any info in regards to the S4 cam follower or replacement schedule, so I just did it anyways. Like I said in the post above and my original post, it's entirely possible that the cam follower is a lifetime item just based off the low wear on mine.

[ModItNow]

I'm going to install my autotech soon after the holidays. After just reading your post I ordered a new cam follower and new bolts for the job! Thanks for the detailed info. Good piece of mind while I'll have it apart anyways.


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[blackjak]

Great write up, this has never really come to mind as preventative maintenance but for $30, it sure is worth the piece of mind as you stated.

[SwankP3RF3ct10n]

OK, so OP, why did you pick the INA one? Was it the design change that drove you to it or that it was cheaper, price wise? For comparison, here's a pic of the old design and new design of the VW OEM ones. Is it me or doesn't it seem like Audi cheapened out on the new design. Old looks machined and new looks stamped metal. WTF?! Obviously the INA ones is the old part number and they're still making it the same way Audi did originally. I have to wonder if INA was the original OEM and they since have changed to another manufacturer now who's making them cheaper. Normally I go with OEM parts, but in this case, I don't feel like putting in a cheaper designed part in that could fail sooner than the original design ones.

https://c-a.d-cd.net/a16e45as-960.jpg

[Hofahome]

For those interested, The OEM S4 cam follower on ECS was like $65, but if you look up the part number on ECS, it also brings it up under porsche, for 1/2 the price. I bought that one and have not had any issues. here it is:

https://www.ecstuning.com/b-genuine-porsche-parts/cam-follower/06l109311~por/

[PenttisHSR]

Well spotted, BOTH followers are Linked in the OP's post under "Parts"
The cheaper one is from INA the more expensive one is OE.
The cheaper one you have linked is "Genuine Porsche" - what's going on here?

Why are these followers a problem on A4's and not on other vehicles?

[b8s4me]

OK, so OP, why did you pick the INA one? Was it the design change that drove you to it or that it was cheaper, price wise? For comparison, here's a pic of the old design and new design of the VW OEM ones. Is it me or doesn't it seem like Audi cheapened out on the new design. Old looks machined and new looks stamped metal. WTF?! Obviously the INA ones is the old part number and they're still making it the same way Audi did originally. I have to wonder if INA was the original OEM and they since have changed to another manufacturer now who's making them cheaper. Normally I go with OEM parts, but in this case, I don't feel like putting in a cheaper designed part in that could fail sooner than the original design ones.

https://c-a.d-cd.net/a16e45as-960.jpg

There's no particular reason for me choosing the INA over OEM, I go to a store called Bap Geon which is basically an Auto Zone for euros/imports only and that's what they had. The OEM design looks like oil would circulate better than the INA, whether that actually matters or not is up for debate.




Well spotted, BOTH followers are Linked in the OP's post under "Parts"
The cheaper one is from INA the more expensive one is OE.
The cheaper one you have linked is "Genuine Porsche" - what's going on here?

Why are these followers a problem on A4's and not on other vehicles?

The A4 cam followers have a plastic end which leads to failure, I don't know why it isn't fully metal like the S4.

Compare the pics I posted to the A4 cam follower below.

https://jhmotorsports.com/shop/catalog/images/B7_A4_20T_Cam_follower_06D109309C.jpg

[SwankP3RF3ct10n]

Well spotted, BOTH followers are Linked in the OP's post under "Parts"
The cheaper one is from INA the more expensive one is OE.
The cheaper one you have linked is "Genuine Porsche" - what's going on here?

Why are these followers a problem on A4's and not on other vehicles?

If you check the part number (original, not revamped version) of the S4 follower, you'll see that many Porsche engines use the same part. That's why it looks the same and functions the same... but ironically, it cost less if you guy the it for a Porsche rather than an Audi... yet another example of bullshit Audi tax, even from the dealers/resellers. [facepalm]


There's no particular reason for me choosing the INA over OEM, I go to a store called Bap Geon which is basically an Auto Zone for euros/imports only and that's what they had. The OEM design looks like oil would circulate better than the INA, whether that actually matters or not is up for debate.





The A4 cam followers have a plastic end which leads to failure, I don't know why it isn't fully metal like the S4.

Compare the pics I posted to the A4 cam follower below.

https://jhmotorsports.com/shop/catalog/images/B7_A4_20T_Cam_follower_06D109309C.jpg

Um, no, if you're talking about the cam follower you posted a pic of, that's not plastic. It's all metal and has a low friction coating on the end of it (the black part) that rides on the cam. The reason it fails more is because it doesn't have a roller like the S4 one does, so it's basically metal on metal riding and the follower's coating up top is only so good. Eventually, it wears away and that's when more wear happens and eventually fails when the cam wears through the metal fully.

Also, I think you might have missed the point on the previous thing about the differences between the INA one for the S4 and the new revised OEM one. Your original you pulled out is like the original Audi OEM one and the INA one.. the revised one just seems cheaply made to me for some reason since it's stamped steel and not nearly as robust looking as the original one. Make sense now?

[PenttisHSR]

Um, no, if you're talking about the cam follower you posted a pic of, that's not plastic. It's all metal and has a low friction coating on the end of it (the black part) that rides on the cam. The reason it fails more is because it doesn't have a roller like the S4 one does, so it's basically metal on metal riding and the follower's coating up top is only so good. Eventually, it wears away and that's when more wear happens and eventually fails when the cam wears through the metal fully.
Brilliant - thanks for the information.

[richardm0025]

Do you have to dip the new cam follower in oil before installing?

[jimrobbington]

Do you have to dip the new cam follower in oil before installing?I would

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[b8s4me]

No. Wouldn't be a bad idea though. Oil will circulate to it when you fire up the car.

[Cerbera9]

recently my HPFP fuel pump has developed a loud ticking noise so today I removed the fuel pump to investigate and found the cam follower jammed in the housing and unable to move along its guide track so I removed the cam sensor housing. Unfortunately in doing this the cam position plate on the end of the camshaft came off too. it looks like its just pushes back on but there are no indication marks as to what position it should be in can anyone advise please?

[Bk808a6]

Sorry to bump such a old thread. But I searched and could not find anything. Just like the poster above. I can't get my cam follower out. I do not want to remove the housing. Is there a way for it to slide out? It feels like it's being locked into place every time I pull it down. Moves quarter inch then nothing. I can move it quarter inch back and forth in housing.

[SwankPeRFection]

Use a magnet. There should be no reason why it won’t slide in and out, outside of just some oil resistance on the sides. It’s like a piston in a cylinder bore, nothing special.

[Nillious]

If the bore and surface of the follower is worn it may be binding up in there. If you get it out make sure you inspect it thoroughly.

[Bk808a6]

Tried with a magnet. It's stuck inside. I ended up putting the new hpfp in since I needed my car back to drive. Works and no weird noises. Just concerning that I was able to remove the CF.

[deejayh]

this is weird - mine pretty much fell out with the fuel pump. 152k miles.

[SwankPeRFection]

Yeah, that shouldn’t be stuck. It should come out. Even though the ones on this engine have an actually roller for the follower, they still need to be changed for high mileage cars, so you’re gonna wanna go back in there and figure out what’s going on before you really have issues.

[Bk808a6]

Yeah I totally agree. Might try again this weekend. Worst case is remove housing but was worried something might break like the other poster had.