Removing and installing fuel pump: VW 1.9 TDI (BJB, BLS, BSU)
Step-by-step removing and installing fuel pump for the VW 1.9 TDI: factory workshop text. What to remove, in what order, and what to check after.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📋 Procedure
ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.
Removing and installing fuel pump
DANGER!
The tandem pump may, under no circumstances, be dismantled as the vacuum part could otherwise malfunction. This would result in the failure of the brake booster.
Special tools and workshop equipment required
Torque wrench 5-50 Nm
V.A.G 1331
Hand vacuum pump with accessories
V.A.G 1390
or
hand vacuum pump
VAS 6213
Water drainage container
V.A.G 1390/1
Spring-type clip pliers
VAS 5024 A
Removing:
Pull supply hose (white marking) and return hose (blue marking) off fuel filter.
Connect
hand vacuum pump with accessories
V.A.G 1390
or
hand vacuum pump
VAS 6213
with
water drainage container
V.A.G 1390/1
to return hose
2
.
Operate hand vacuum pump until no more fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump.
Remove air filter housing with air mass meter and connecting pipe .
Remove bolt
arrow A
and pull air filter housing upwards out of mounting.
Pull brake booster vacuum line
1
off tandem pump
4
.
Pull supply hose
2
(white marking) and return hose
3
(blue marking) off tandem pump
4
.
Unscrew securing bolts
arrows
.
Remove tandem pump
4
from cylinder head.
Installing:
Installation is carried out in the reverse order; note the following:
Note
Ensure that tandem pump coupling seats properly in camshaft.
Renew tandem pump seal.
Install tandem pump and tighten upper securing bolts to 20 Nm.
Tighten lower securing bolts to 10 Nm.
Carry out leakage test
Anchor
.
Connect return hose (blue marking) to return connection
3
of tandem pump.
Connect supply hose (white marking) to supply connection
2
and brake booster vacuum line
1
to tandem pump
4
.
Connect supply hose (white marking) to fuel filter.
Connect
hand vacuum pump with accessories
V.A.G 1390
or
hand vacuum pump
VAS 6213
with
water drainage container
V.A.G 1390/1
to return hose
2
.
Operate
hand vacuum pump
V.A.G 1390
or
hand vacuum pump
VAS 6213
until fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump.
Connect return hose (blue marking) to fuel filter.
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.