Removing and installing high-pressure pump, engine codes BLG and BMY — VW

🧭 Before you start

Reduce fuel pressure in the high-pressure section, remove the engine cover and turn the crankshaft to TDC on cylinder 1. Disconnect the fuel supply line, take off the pressure pipe and the intake connecting pipes with J808, then remove the line guide bolt and clip and loosen both union nuts of the high-pressure line. Undo the three pump bolts evenly and lift out the pump and roller tappet. Refit the oiled tappet, a new lubricated O-ring and the pump, tightening its bolts evenly. Run the unions up by hand, refit the guide bolt and clip, then torque both union nuts to 18 Nm with counterhold.

Fits: VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

• Opens: coolant
• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• Release high-pressure fuel down to residual pressure before opening any line on the high-pressure side.
• Set the crankshaft to cylinder 1 TDC; do not drain coolant or remove the camshaft sealing caps.
• Renew the pump O-ring every time and moisten the roller tappet with clean engine oil.
• Remove and tighten the three pump bolts evenly to avoid tilting the pump.
• Counterhold the threaded connections while tightening both high-pressure union nuts to 18 Nm.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📐 38 workshop diagrams for BLG

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar).Prior to opening the high-pressure area, e.g. when removing the high-pressure pump, fuel rail, injectors, a fuel line, or the fuel pressure sender G247, the fuel pressure in the high-pressure area must be reduced to a residual pressure of approx. 6 bar. The appropriate procedure is described in the chapter on "“releasing pressure in the high-pressure section of the fuel system”". — Remove engine cover panel .
2. Turn crankshaft in direction of engine rotation to 1st cyl. TDC (do not drain coolant and do not remove sealing caps for camshafts).
3. Pull fuel supply line (right arrow) from high-pressure pump. [Note: Catch escaping fuel in a cloth.]
4. Remove securing bolts (1).
5. Detach spring-type clips and pull off hose (2) on activated charcoal filter system solenoid valve 1N80 and pressure pipe (3).

6. Unscrew securing bolts for pressure pipe (3) at turbocharger and valve timing housing and pull pressure pipe (3) off.
7. Pull off all connectors and hose connections at intake connecting pipes (4) and regulating flap control unit J808.
8. Unscrew intake connecting pipe securing bolts (arrows) and pull intake connecting pipes upwards with regulating flap control unit J808.
9. Unscrew line guide bolt (2) and take clip (4) off high-pressure line. [Note: When loosening union nuts, counterhold threaded connections on high-pressure pump and on lower part of intake manifold/fuel rail using a wrench.]
10. Loosen union nuts (3) and (1) of high-pressure line.
11. Remove securing bolts (1), (2) and (3) equally.
12. Pull high-pressure pump (3) and roller tappet (1) out of camshaft housing. [Note: Moisten high-pressure pump roller tappet with clean engine oil.The high-pressure pump O-ring must always be renewed.]
13. Slide roller tappet (1) into camshaft housing.
14. Insert new, lubricated O-ring (2) in groove of high-pressure pump (3).
15. Place high-pressure pump (3) onto camshaft housing.
16. Tighten securing bolts (1), (2) and (3) equally.
17. Tighten union nuts of high-pressure line (1) and (3) hand-tight.
18. Install line guide bolt (2) and press clip (4) onto high-pressure line. [Note: When tightening union nuts, counterhold threaded connections on high-pressure pump and on intake manifold lower part/fuel rail using a wrench.]
19. Tighten union nut (1) of high-pressure line to 18 Nm. — 18 Nm (13 lb-ft)
20. Tighten union nut (3) of high-pressure line to 18 Nm. — 18 Nm (13 lb-ft)
21. Secure fuel supply line and connector (arrows) on high-pressure pump.
22. Install engine cover .

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