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 7 (1.9L - DIESEL FUEL INJECTION - ALH, 2V TDI (A4 PLATFORM))DIESEL DIRECT 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.
- Observe rules for cleanliness, see RULES FOR CLEANLINESS
- Removing and installing injection pump, see INJECTION PUMP, REMOVING AND INSTALLING
- Dynamically checking and adjusting injection pump, see START OF INJECTION, DYNAMICALLY CHECKING AND ADJUSTING
- Always replace seals and O-rings
The following list pertains to Fig 1.
- Oil seal
- Always replace
- Pipe union, 25 Nm
- For supply line
- From fuel filter
- Injection pump
- With quantity adjuster (metering)
- With Fuel Temperature Sensor -G81- *, checking, see FUEL TEMPERATURE SENSOR -G81-, CHECKING
- With Quantity Adjuster -N146-*, checking, see MODULATING PISTON DISPLACEMENT SENSOR -G149- AND QUANTITY ADJUSTER -N146-, CHECKING
- With Modulating Piston Displacement Sensor -G149-*, checking, see MODULATING PISTON DISPLACEMENT SENSOR -G149- AND QUANTITY ADJUSTER -N146-, CHECKING
- Fuel shut-off valve -N109-*/**, 25 Nm
- Union
- For return
- Return line
- To control valve/fuel filter
- 25 Nm
- Injector lines
- Tighten to 25 Nm
- Remove and install with 3035
- Always remove two-part linework complete
- Do not alter shape
- Line union, 45 Nm
- With pressure valve
- 25 Nm
- Injector
- Removing and installing, see INJECTORS, REMOVING AND INSTALLING
- Checking, see INJECTORS, CHECKING
- For No. 3 cylinder with Needle Lift Sensor -G80-*
- Checking needle lift sensor, see NEEDLE LIFT SENSOR -G80-, CHECKING
- 20 Nm
- Retainer
- Mounting
- Copper washer
- Always replace
- 10 Nm
- Cold Start Injector -N108-*/**
- Checking injection timing control range, see DIESEL INJECTION TIMING CONTROL RANGE, CHECKING
- Gasket
- Always replace
- Strainer
- Clean strainer if soiled
- Timing control cover
- If leaking, replace gasket, see INJECTION TIMING DEVICE COVER GASKET, REPLACING
- Sleeve
- With nut
- Compact bracket
- For injection pump, generator and power steering pump
- For vehicles without air conditioner
- Removing and installing:
- Removing and installing compact bracket on vehicles with air conditioner:
- 25 Nm
- Injection pump sprocket bolts
- Take note of different types and torque settings, see Figure
- Injection pump sprocket
- Take note of different types (Part No.), see Figure
- Removing and installing, see INJECTION PUMP, REMOVING AND INSTALLING
- Nut
- For hub
- Do not loosen or the injection pump basic setting may be altered. This cannot be reset with normal workshop equipment.
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.