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 17 (1.9L - TDI AND TDI PD GENERIC SCAN TOOL, ENGINE CODE(S): ALH, BEW (A4 PLATFORM))23 DIESEL FUEL INJECTIONDIESEL-DIRECT FUEL INJECTION SYSTEM, SERVICINGPUMP-INJECTOR UNIT, CHECKINGTEST SEQUENCE

2002 Volkswagen Golf GLS, 2.0 K, Standard

Test sequence

2002 Volkswagen Golf GLS, 2.0 K, StandardSECTION Test sequence

WARNING: This page is about a different variant/trim than selected.

Disconnect harness connector for Pump-Injector Unit from cylinder head. Refer to item 10 in Component Locations, overview (vehicles with engine code BEW) .

Fig 1: Identifying Pump-Injector Unit Valve Connector Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check resistance of Pump-Injector Unit valves between connector terminals.

Cyl. 1: Terminals 7 + 5

Cyl. 2: Terminals 7 + 3

Cyl. 3: Terminals 7 + 2

Cyl. 4: Terminals 7 + 6

Specified value: 0.1 to 1.0 Ω

Check wires for short circuit to each other as well as to vehicle Ground (GND).

Specified value: ∞ Ω

If specified value is obtained:

Check wires to control module according to wiring diagram. Refer to Check wires to control module .

If specified value is not obtained:

Remove upper toothed belt guard and cylinder head cover.
Pry off connectors of all 4 pump-injector units using a screwdriver. In order to avoid canting, support opposite side of connector with light finger pressure.

Fig 2: Checking Resistance Of Pump-Injector Unit Valves Between Connector Terminals At Pump-Injector Unit Valves

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check resistance of Pump-Injector Unit valves between connector terminals at Pump-Injector Unit valves.

Specified value: approx. 0.5 Ω

If specified value is not obtained:

Replace malfunctioning Valve for pump/injector, cylinder 1 -N240- to Valve for pump/injector, cylinder 4 -N243-. Refer to Pump-Injector Unit, removing and installing , removing and installing Pump-Injector Unit.
Erase DTC memory of control module for Diesel-Direct fuel injection system. Refer to Diagnostic mode 4: Reset/erase diagnostic data .
Generate readiness code.

If specified value is obtained:

Fig 3: Identifying Pump-Injector Unit Valve Connector Terminals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check wires between harness connector for Pump-Injector Unit and all 4 connectors (terminal 2) for open circuit.

Cyl. 1: Terminal 2 (gray) + terminal 5

Cyl. 2: Terminal 2 (red) + terminal 3

Cyl. 3: Terminal 2 (yellow) + terminal 2

Cyl. 4: Terminal 2 (white) + terminal 6

Wire resistance: max. 1.5 Ω

Check wires between harness connector for Pump-Injector Unit and all 4 connectors (terminal 1) for open circuit.

Terminal 1 (brown) + terminal 7

Wire resistance: max. 1.5 Ω

Check wires for short circuit to each other.

Specified value: ∞ Ω

RENDER: 1.0x

NO RELATED

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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.