Volkswagen Workshop Service and Repair Manuals

Removing and installing high-pressure pump (engine codes BLF, BLN, BLP) Special tools and workshop equipment required

t  Torque wrench (4…20 Nm) -V.A.G 1410-

t  Spring-type clip pliers -VAS 5024A- Prerequisite l  Engine must be cold. Removing –  Remove air filter → Chapter.   WARNING Fuel supply lines are under pressure! Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Separate fuel supply line -arrow-.

–  Pull connector and fuel supply line -arrows- off high-pressure pump.   Note Catch escaping fuel in a cloth.

–  Remove wiring guide -2- and take clip -4- off high-pressure line.   Note Use a spanner to counterhold threaded connections on high pressure pump and on lower part of intake manifold when loosening union nuts. –  Loosen union nuts -1- and -3- of high-pressure line.

–  Remove securing bolts -1-, -2- and -3- equally.

–  Pull high-pressure pump -3- and bucket tappet -1- out of camshaft housing. Installing Installation is carried out in the reverse order. When installing, note the following:   Note t  Moisten high-pressure pump bucket tappet with clean engine oil. t  The high-pressure pump O-ring must always be renewed. –  Push bucket tappet -1- into camshaft housing.

–  Insert new, lubricated O-ring -2- in groove of high-pressure pump -3-. –  Place high-pressure pump -3- onto camshaft housing. –  Tighten securing bolts -1-, -2- and -3- equally.

Specified torque: 10 Nm

–  Tighten union nuts of high-pressure line -1- and -3- hand-tight. –  Install wiring guide -2- and fit clip -4- on high-pressure line. Specified torque of wiring guide securing bolt: 8 Nm   Note Use a spanner to counterhold threaded connections on high-pressure pump and on lower part of intake manifold when tightening union nuts.

–  Tighten union nut -1- of high-pressure line to 18 Nm. –  Tighten union nut -3- of high-pressure line to 18 Nm.

–  Secure fuel supply line and connector -arrows- on high-pressure pump.

–  Reconnect fuel supply line -arrow-. –  Install air filter → Chapter.