Installing
Note: Install a new pump-injector unit, also replace the corresponding adjustment bolt in rocker arm.
For every procedure that requires adjustment of the pump-injector unit, the adjustment screw in the rocker lever and the ball pin of the pump-injector unit must be replaced.
New Pump-Injector Units are shipped with O-rings and heat protection seal.
Install the pump-injector unit again, replace the O-rings and the heat protection seal Pump Injector Unit O-Rings, Removing and Installing .
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.
Using uniform pressure, push the pump-injector unit into the cylinder head seat onto the 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 the new bolt into the tension block so far that the pump-injector unit can still be lightly turned.
Now align Pump-Injector Unit at right angle to thrust bearing of camshaft.
Using a caliper gauge (measuring range minimum 400 mm), check dimension "a" from the outer edge of the cylinder head to the round surface of the 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 the securing bolts to 12 Nm and turn an additional 270 degree ( 3 / 4 rotation, additional rotation may occur in several stages).
Install rocker arm axle and tighten new securing bolts as follows:
First hand-tighten the inner bolts - 2 - , then the outer bolts - 1 - equally; then tighten in the same sequence to 20 Nm and 90 degree ( 1 / 4 turn).
Place a dial gauge as shown onto the adjustment screw of the pump-injector unit.
Rotate crankshaft in direction of engine rotation until rocker arm roller stands at camshaft point. Roller side - arrow A - is positioned at the highest point, dial gauge - arrow B - is positioned at the lowest point
Remove the dial gauge.
Now turn adjustment bolt into rocker arm until significant resistance is noticeable (Pump-Injector element stands at stop).
Turn back adjustment bolt from stop approximately 180 degree
Hold adjustment bolt in this position and tighten lock nut to 30 Nm.
SOURCE: 2003 vw jetta tdi fuel filter
It is on the passenger side right behind the washer fluid fill tube. You can follow the fuel lines (look like 1/4" black tubes, some are clear) from the injector pump to it. It is a caniser a bit bigger than a normal looking oil filter and sits between the washer bottle and the metal that forms the wheel well. It is held in by a screw type clamp about half way down the cylinder. Probably isn't the fuel filter unless there is air in the lines to the injector pump or they didn't bother to fill the fuel filter up with diesel after putting it in. There is not a fuel pump in the tank in these cars so everything is sucked up by the injector pump and it needs to be primed properly.
SOURCE: transmission fluid level check 02 jetta tdi auto
VW didn't put a "dipstick" on the trans for whatever reason. You technically have to use the VW Vag-Com scanner to properly check the trans fluid level as VW says it has to be checked at a specific temperature. But there is a "shade-tree" workaround. Start the car and leave the engine running the throughout the entire procedure. You have to get the trans fluid warm-a little under normal operating temp. 95F-104F is what you want-you can attain this after letting the car idle for 8 or so minutes. Continuing, leave the trans in park, and make sure you are on as level of a surface as possible. Then loosen the allen plug on the bottom of the trans pan. You will then see another plug. Remove this plug. Fluid should just trickle out of the hole if it is at the proper level. If it trickles out, you are good. If it doesn't you need to add fluid. Add VW spec ATF through the fill port.The fill port on the top front of the trans is capped off by a red cap and is very visible. Very carefully pry the cap off and then wiggle the plug out. I'd highly suggest having a spare red cap on hand-VW dealer has them. Then you can pour fluid into the trans. Add a little bit at at time, and all the while watching for the fluid to tricke out of the trans plug hole. When it trickles out, replace the inner plug and then the outer plug. That's it. Recheck after driving the car for a few miles. FYI- A flud and filter swap on the the VW auto trans takes 3 liters, so keep that in perspective. I hope this helps you out.
SOURCE: 2006 volkswagon timing belt jetta tdi turbo diesel
i can walk u through doing a t belt. But if u are not sure if u are able to do it DO NOT DO IT cause if u are wrong if cause a lot of engine damage.
SOURCE: 2002 Jetta TDI radio fuse number?
The Fuse number is..... drum roll..... 42 .... And you don't even have to have a dead battery for the radio to lock up. I have owned my 2002 tdi since New... and about 4 or 5 times a year radio dies. When you remove the fuse... don't immediately put it back in.... The capacitors in the radio have not fully discharged and if you put the fuse right back in.. chances are it will stay locked. I count to 15... then put the fuse back in. Close fuse door.... Operate radio normally till next lock up.... then repeat process. So you won't forget the fuse number... write #42 in the white space of your fuse location sticker that is attached to the inside of the fuse door. Hope this helps... tried to be detailed.
SOURCE: p0106 map sensor code on tdi
02 jetta map sensor code p0106 and faulty boost sensor code p0238
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This tdi injector pump needs to be pinned. You need the proper tools. There's a pin for the pump and a locking device for the camshaft and another locking device for the crankshaft.
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