Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLKSWAGEN2002GOLF GLS, 2.0 K, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 11 (1.9L - DIESEL FUEL INJECTION - TDI, ALH, BEW (GENERIC SCAN TOOL) (A4 PLATFORM))DIESEL FUEL INJECTIONDIESEL-DIRECT FUEL INJECTION SYSTEM, SERVICINGINJECTION PUMP, SERVICINGNOTES
2002 Volkswagen Golf GLS, 2.0 K, Standard
Injection pump, servicing: Notes
2002 Volkswagen Golf GLS, 2.0 K, StandardSECTION Notes
WARNING: This page is about a different variant/trim than selected.
- Note rules of cleanliness, see RULES OF CLEANLINESS
- Always replace sealing rings and O-rings
The following list pertains to Fig 1.
- Seal
- replace
- Connecting piece 25 Nm
- For supply line
- from fuel filter
- Injection pump
- With quantity adjuster
- With Fuel Temperature Sensor -G81- *,Checking, see FUEL TEMPERATURE SENSOR, CHECKING
- With Quantity Adjuster -N146- *,Checking, see MODULATING PISTON DISPLACEMENT SENSOR AND QUANTITY ADJUSTER, CHECKING
- With Modulating Piston Displacement Sensor -G149-*,checking, see MODULATING PISTON DISPLACEMENT SENSOR AND QUANTITY ADJUSTER, CHECKING
- Fuel Cut-off Valve -N109-, 25 Nm
- Connecting piece
- For return line
- Return line
- To regulator valve/fuel filter
- 25 Nm
- Injection lines
- Tighten to 25 Nm
- use 3035 ring spanner to remove and install
- Always replace two -piece wiring set completely
- Do not change bend-shape
- Connecting piece, 45 Nm
- With pressure valve
- 25 Nm
- Fuel injector
- Removing and installing, see INJECTORS, REMOVING AND INSTALLING
- Checking, see INJECTORS, CHECKING
- For cylinder 3 with needle lift sensor
- Check Needle Lift Sensor -G80-*, see NEEDLE LIFT SENSOR, CHECKING
- 20 Nm
- Tension bracket
- Mounting bracket
- Copper washer
- replace
- 10 Nm
- Cold Start Injector -N108-*
- Checking, see COLD START INJECTOR, CHECKING
- Seal
- replace
- Strainer
- Clean strainer if dirty
- Timing control cover
- Replace seal if leaking.
- Socket
- with nut
- Bracket
- 25 Nm
- Securing bolts of injection pump sprocket
- Note different versions and tightening torques, see Versions of securing bolts for injection pump sprocket
- Injection pump sprocket
- Note different versions (replacement part numbers), see Versions of securing bolts for injection pump sprocket
- Mounting nuts
- For hub
- Must not be loosened under any circumstances. Otherwise, basic setting of the injection pump will be altered, this cannot be reset with normal workshop equipment
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.