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1999 Volkswagon beetle turbo diesel injection pump

Fuel is coming into injection pump, but it is not coming out into the injection lines to the injectors.

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  • Kevin Blair
    Kevin Blair May 11, 2010

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  • Master
  • 409 Answers

Was any work just done to this car? Timing belt? It is rare that these pumps go bad but I have seen a few shell out. If you are not familiar with the ALH diesel engine I would not try to replace it. You should take it to a shop that specializes in VW's. 

Posted on Dec 29, 2008

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1 Answer

How do you bleed a diesel pump jeep Cherokee turbo diesel 3.1 5 cylinder 2001


we dont have this engine here, USA.
but i have the WG jeep book,
starting page 12 , chapter 14


FUEL INJECTION PUMP BLEEDING
(1) If the fuel injection pump has been replaced,
air should be bled at the overflow valve before
attempting to start engine.
(a) Loosen the overflow valve (Fig. 18) at the
rear of the injection pump.
(b) Place a towel below the valve.
WARNING: WHEN CRANKING THE ENGINE TO
BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
CAUTION: Do not engage the starter motor for
more than 30 seconds at a time. Allow 2 minutes
between cranking intervals.
(2) Crank the engine for 30 seconds at a time to
allow air trapped in the injection pump to vent out
the fuel injector drain tubes. Continue this procedure
until the engine starts. Observe the previous WARNING
and CAUTION.
(3) Tighten overflow valve.
HIGH-PRESSURE FUEL LINE BLEEDING
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
-PRESSURE FUEL OF APPROXIMATELY 45,000 KPA
(6,526 PSI) TO EACH INDIVIDUAL INJECTOR
THROUGH THE HIGH-PRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE
THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE
CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE
FUEL LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Bleed air from one injector at time.
(1) Loosen the high-pressure fuel line fitting at
the injector (Fig. 19).
(2) Crank the engine until all air has been bled
from the line. Do not operate the starter motor
for longer than 30 seconds. Wait 2 minutes
between cranking intervals.
(3) Start the engine and bleed one injector at a
time until the engine runs smoothly.

end quote.
pump timing is on next page
or tank filter line priming before. above.

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1 Answer

2004 5L Hiace fails to start however whines.


this is the first thing i would do since it has not run for a long time.
1 make sure it has fuel, check filter, loosen the bolt securing the fuel line to the pump and see if fuel is coming out, if it does you have fuel in the injection pump. retighten.
2 loosen nuts on injection lines to injectors 4 if you have 4 cyl. eng.
and crank the engine (start) until you see fuel coming out from each line then re-tighten lightly. start the engine*, it may take a while for the engine to run if the glow plugs are not working properly. once the engine is running its time to bleed or purge air out of the line, to do this
loosen one at a time the nut you have re-tightened lightly until fuel and air come out, tighten when no visible air bubble only solid fuel stream. do this on the rest of the injectors, you will feel the engine run smooth.

*if there is no fuel coming out after continuous cranking the engine for 30 sec to a minute, injection pump may have a problem possibly the rotor vanes inside the pump is stuck due water in fuel and engine not running for a long time. you may have to have the injection pump overhauled and recalibrated.

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2002 beetle tdi check engine light on. computer said it was glow plug problem i replaced glow plugs and harness, light still comes on


replace brake light S.w , after you check rear brake light is ok , check injection pump have water in side with fuel .dis connect fuel line from injection pump use New fuel with injector cleaner .

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Engine turns over on my 2003 Jetta 1.9L TDI but does not start. New battery , all lights are working. Changed fuel fillter and put diesel in it to wet it, but still does not start. It did start once and...


When were the glow plugs last changed?

They sit over the cylinder like spark plugs and warm the diesel before it goes into the inlet manifold, greatly assists starting.

May 17, 2010 | 2003 Volkswagen Jetta TDI

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My golf 1.9 tdi is miss-firing


Check the fuel lines, fuel filter, what is the mileage? If it is high than it might a sign of injector pump or injectors.

Apr 08, 2010 | 2002 Volkswagen Golf

1 Answer

Remove and install diesel fuel injector


First, keep everything as clean as possible. Contamination below 30 microns, which cannot be seen by humans, can destory a diesel fuel injection system. Clean everything off anything having to do with connections on the fuel system and cover any connections left open.

Begin by removing the intake manifold. This will remove the clips holding the injection lines passing underneath and around the intake runners. After removing the manifold, cover the openings in the cylinder head (I use wadded-up paper towels).

Next, remove the clips at the brackets on the injection lines closer to the injectors.

Loosen all of the injection connections at the injectors. Do not remove the lines.

You can remove the water crossover tube if it is in your way, but drain about a 1/2 gallon of coolant before your remove the crossover.

Remove the oil fill tube from the timing cover. Turn the engine clockwise, using a 15/16" socket and ratchet (or breaker bar) on the center bolt of the crankshaft. As you turn the engine over, a bolt will show up at the opening where the oil fill tube was removed. Remover the bolt and keep turning the engine over until you have removed all three bolts. Do NOT use the starter to turn the engine over and, after removing the third bolt, do NOT turn the crankshaft any more.

On top of the timing cover, behind the rounded top, is the place where the injection pump is bolted to the cover from the back side. Clean the top of the timing cover where it meets the injection pump and look for a thin line scribed into the cover and one on the injection pump. Note the position of the two lines (they are usually aligned) for reassembly.

Remove the throttle cable assembly from the injection pump. Remove all the wires from the pump and note which connection the big pink wire goes to. The other wires will be green. Remove the return hose at the top of the injection pump.

There are three nuts holding the injection pump to the timing cover and you will need a 15mm socket and/or wrench to remove them. When you do, the injection pump and injection lines can be removed as a unit. Note the position of the driveshaft of the injection pump to set the new one the same way. If you are not going to put things back together right away, cut up a plastic garbage bag and make covers for the injectors. Secure the covers with rubber bands or nylon cable ties to keep dirt out of the injectors.

Carefully transfer the injection lines to the new pump. It is possible to cross them up so pay close attention while moving the lines. Transfer the fuel inlet pipe to the new pump and whatever device is mounted on the passenger side of the old injection pump to the new pump.

Get a new injection pump to timing cover gasket and install it over the timing cover studs. Install the new injection pump after setting the driveshaft to match the holes in the gear inside the timing cover. The pump can only be installed one way since it is indexed to the gear. Reinstall the nuts on the studs and set the timing marks to the same position they were when you removed the old injection pump (the lines on top of the timing cover and the flange of the injection pump). Tighten the mounting nuts. Make sure that all the injection lines line up at their injectors, but do not tighten the connections at the injectors yet.

Put the first bolt back into the gear through the oil fill tube hole. Hand tighten it and then turn the crankshaft clockwise as before to install the remaining two bolts. Then, tighten all the bolts securely and resinstall the oil fill tube. Reinstall the throttle connections on the injection pump.

Install a new piece of 1/4" fuel line from the fuel filter to the injection pump (the old one is usuall brittle since it never gets changed). Remove the covers over the opening in the cylinders heads and reinstall the intake manifold using new gaskets.

Reinstall all the injection line clips that were removed and the coolant crossover tube (if you removed it and don't forget to add coolant to the radiator). Reconnect all the wiring on the injection pump, except for the big pink wire. Install a piece of clear tubing on the top of the injection pump and connect it to the return tee in front of it (where you removed the rubber hose from the old injection pump).

Now comes the fun part: Disconnect the glow plug relay connector (two small wires in a connector) from the middle of the relay. The relay is usually on the driver's fender and close to the battery.

Crank the engine, in short bursts, until you see fuel in the clear tubing on top of the injection pump. When you do, reconnect the big pink wire on the injection pump. Continue to crank the engine in short bursts (allowing the starter to rest between cranking cycles) until you see fuel dripping out of the injection lines at the injectors. When you do, tighten the connections where fuel is dripping. When all lines have been tightened, reconnect the glow plug relay connector. Remove the clear tubing on top of the injection pump and reinstall the fuel line that was removed from that location.

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The engine may run rough or stall at first but it should smooth out after all the remaining air comes out of the system.

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Intake manifold: 25-37 ft-lbs
Gear bolts: 13-20 ft-lbs
Injection pump mounting nuts: 25-37 ft-lbs
Injection lines: 15-24 ft-lbs ("wrench tight" is fine)
Injection pump fuel inlet fitting: 15-20 ft-lbs

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