Question about 2002 Volkswagen Jetta TDI

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2003 TDI 160,000 km, manual transmission

Engine quit after making a 90 " corner on gravel road. Engine cranks OK, check fuel to injectors but pressure to low to open injector. Filters ok, shut-off valve ok, no faults as indicated by scan tool.
Question, does the ECM control the injector pump and if a failure of the T-30 power supply relay?? cause the pump rack to return to a neutral position and therefore prevent the pump from generating adequate fuel pressure to open the injectors? Or is this a mechanical problem in the injector pump?
Some assistance would be most helpful as it is winter here and need the car.

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Hi, I realy believe you are low on full & by making the turn you got air in the system. Add fuel, then get an assistant to cranck the engine for you while you blead the injectors throughly. One by one, till you see no bubbles coming out. If you have air in the diesel, preasure will be very low as you described. Hope that does it.

Posted on Dec 11, 2008

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Reset fuel pump enersha switch in trunk?

Posted on Dec 08, 2008

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1 Answer

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There is no throttle body on a TDI, but continuing to crank you engine with no fuel pressure will absolutely fry your pump and/or injectors (An '03 could be either an ALH or a PD engine, - different fuel injection systems, but same disastrous result in either).
Here's my .02:
DO NOT let a VW dealer touch your TDI. They commonly throw parts at it until the problem either goes away or they throw up their hands and say "I dunno". Either way, people routinely waste a boatload of time and money with no relief when taking their TDI to a VW dealer.
Go to TDIClub.com and look for a trusted TDI Guru near you (there's a list by state) and have one of these guys look at it. They're very helpful and more knowledgeable than 95% of VW dealers.
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You have a faulty residual fuel sensor. This is part of the warm start system. A small amount of fuel is held under pressure so as there is pressure in the system to start the car. Pressure varies due to heat. Yours is failing under heat. When cold it starts just fine.

Go to the library ask for the Robert Bentley (authors) service manual for your model and yr. If they don't have it they will get it from another branch (free). Look under fuel system and you will see all the details on the system.

It is not hard to check, remove and replace.






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