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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, REMOVING AND INSTALLINGINSTALLING
2002 Volkswagen Golf GLS, 2.0 K, Standard

Pump-Injector Unit, removing and installing: Installing

2002 Volkswagen Golf GLS, 2.0 K, StandardSECTION Installing
WARNING: This page is about a different variant/trim than selected.
NOTE:
  • Install a new Pump-Injector Unit, also replace the corresponding adjustment bolt in rocker arm.
  • For each step which requires an adjustment of Pump-Injector Unit, adjustment bolt in rocker arm and also the ball pin for Pump-Injector Unit must be cleaned and examined for traces of wear. If there is wear, ball pin and adjustment bolt must be replaced.
  • Grease contact surface between ball pin and adjustment bolt with G 000 100.
  • New Pump-Injector Units are shipped with O-rings and heat protection seal.
  • If old Pump-Injector Unit is re-installed, the O-rings and heat protection seal must be replaced.
  • Before installing Pump-Injector Unit, check that the three O-rings, heat protection seal and securing ring are seated properly.
NOTE: O-rings must not be twisted on themselves.
  • Oil O-rings and insert Pump-Injector Unit with great care into cylinder head seat.
  • Drive Pump-Injector Unit in using uniform pressure into cylinder head seat until stop.
  • Insert tension block into lateral slot of Pump-Injector Unit.
NOTE: If Pump-Injector Unit does not stand at right angle to tension block, securing bolt can loosen and thereby cause damage to Pump-Injector Unit / cylinder head.
  • Align Pump-Injector Unit as follows.
  • Screw in the new securing bolt as far into tension block so that the Pump-Injector Unit can still be turned lightly.
  • Now align Pump-Injector Unit at right angle to thrust bearing of camshaft.
Fig 1: Identifying Dimension "a"
GW00000407Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Using a caliper gauge (measuring range minimum 400 mm), check dimension "a" from outer edge of cylinder head to round surface of Pump-Injector Unit.
Cylinder  Dimension "a" 
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
  • Re-align Pump-Injector Unit if necessary and tighten securing bolt as follows:
  • Tighten securing bolt to 12 Nm and

270 ° (3/4 turn) (additional rotation can occur in several stages).

Fig 2: Identifying Bolts
GW00000358Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Install rocker arm axle and tighten new securing bolts as follows:
  • Tighten inner bolts -2- hand-tight, then outer bolts -1-. Then in the same sequence,

Tighten to 20 Nm plus an additional 90 ° (1/4 turn).

Fig 3: Identifying Special Tool VW 387
GW00000408Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Set a dial gauge onto adjustment bolt of Pump-Injector Unit as shown.
  • Rotate crankshaft in direction of engine rotation until rocker arm roller stands at camshaft top.

Roller side (arrow -A-) stands at highest point

Dial gauge (arrow -B-) stands at lowest point

  • Remove dial gauge.
  • Now turn adjustment bolt into rocker arm until significant resistance is noticeable (Pump-Injector element stands at stop).
Fig 4: Adjusting Screw 225 Degrees
GW00000409Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Turn back adjustment bolt from stop approx.

225 °.

  • Hold adjustment bolt in this position and tighten lock nut to

30 Nm.

  • Connect connector to Pump-Injector Unit and install cylinder head cover and toothed belt guard.
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.