2002 ALH Jetta injection pump replacement

Twinkieflyer

Well-known member
Joined
Nov 14, 2017
Location
Blacksburg, Virginia
TDI
2002 ALH 5spd
I have started smelling some diesel leakage around the injection pump. Not quite sure where the leak is but it is pretty small, just enough to make things a little wet and smell but nothing running out.
I ran across a guy (with a good reputation) that had an 11mm pump off an automatic ALH which he says had a seal kit put in it a year ago.
I have to do my work myself even though I am not very experienced because there really isn’t a shop near me. When I needed a water pump and timing belt on a 2015 Jetta TDI I dropped it off at a shop and after 4 days they said they were afraid to do it. I ended up doing it myself in about 6 hours being very careful. Helped a lot that I found a video from a guy in UK that showed how to get the timing belt on without pulling the camshaft gear like in the video I bought from one of the vendors.
Anyway, so I am wondering if I should try to put this on as is or just send it for overhaul. I don’t want to mess with it twice as I am letting my daughter drive it.
I also realize this is going to be harder than the 2015.
What you guys think and who overhauls these? I can stand a few weeks.
Thanks,
Bill Harris
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB , added an 06 NB DSG
You can do the reseal while in the car with a kit from diesel geek and the videos from runonbeer .
I believe that it’s in the how to section.
Not hard to do just need to be real clean about it.
 

Twinkieflyer

Well-known member
Joined
Nov 14, 2017
Location
Blacksburg, Virginia
TDI
2002 ALH 5spd
Oh, I had no idea. I figured it was much more involved than that.
Maybe I should just put it in. Is swapping as complex as replacement of timing belt?
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
Is swapping as complex as replacement of timing belt?
You need to use the locking tools to lock timing, release tension on the belt, and take the camshaft sprocket loose. Then replace the pump, lock it, and re-tension the belt - so many of the same steps as a timing belt change but no need to mess with the engine mount.

Depending how many miles the belt has on it, you might want to do a full TB job while you are there.
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB , added an 06 NB DSG
P2B beat me to it.
 

KrashDH

Top Post Dawg
Joined
Dec 22, 2013
Location
Washington
TDI
2002 Golf
Oh, I had no idea. I figured it was much more involved than that.
Maybe I should just put it in. Is swapping as complex as replacement of timing belt?
It's not hard at all to swap a pump in, way easier than a full TB job. I pulled my 10mm out and swapped it with the 11mm I bench rebuilt
 

Twinkieflyer

Well-known member
Joined
Nov 14, 2017
Location
Blacksburg, Virginia
TDI
2002 ALH 5spd
I don’t suppose there is any way to get the pump on without taking off the cam sprocket like I did on the 2015. And are the locking tools different? I don’t have a vag-com so that would be a major expense for one job.
The 2015 went back together just by backing off the tensioner and putting the top idler in last.
The timing belt and water pump only have 40k on them but the guy who did them is no longer available.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
I don’t suppose there is any way to get the pump on without taking off the cam sprocket like I did on the 2015. And are the locking tools different? I don’t have a vag-com so that would be a major expense for one job.
Belt tension cannot equalize unless the cam sprocket can move. The tools are ALH specific but can possibly be borrowed or rented.

VCDS is indispensable if you plan to maintain VWs, but you can get by with the free light version and and a twenty dollar cable for this job.

.
 

Twinkieflyer

Well-known member
Joined
Nov 14, 2017
Location
Blacksburg, Virginia
TDI
2002 ALH 5spd
Sooo, long pause. I gave up on putting in the 11mm pump because I don't have VCDS. I figured I would just put the seal kit in the 10mm pump but reading it looks like I will probably have to do a timing adjustment for that as well since the writeups are saying even if I mark the housings it will probably need to be checked and adjusted.
So I had an old cable so tried the VCDS lite download but it looks like it won't do anything unless it is registered and they won't register it unless I am in the customer database which I am not. Totally understandable, but now I am faced with either pray the marks work out or buy the software.
Timing is a bit of an issue too with holidays coming on quickly. I don't want my daughter driving the 02 Jetta with diesel leaking all over the engine and of course a senior in HS doesn't want to ride the bus.
I am ok with buying the software for $99 but its a bit hard to tell if the lite version will work. Seems like I have to buy it to get enough functionality to check timing.
I really wish I could take it to someone but there is absolutely no one who wants to work on a diesel VW near Blacksburg. All the shops are afraid of it. The shop listed in the shop list in Floyd went out of business 4 years ago.
Should I just buy the lite software or something better?
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
I know spending extra money at this time of the year is something of a bitter pill timing-wise, but instead of the $99, I'd spend $199 and get the newer/newest version of the VCDS dongle and the full software.
It's limited to only three VINs, but sounds like that'll be fine with you. SO much better than monkeying around with stunted "lite" version of the software.

As others have mentioned, the seal kit install is pretty straightforward if you watch the videos (Here's a link to direct download of all seven parts combined into one video [BEWARE: 5.3GB] that @runonbeer did) and then UNDERSTAND what you're doing before jumping in.
If you did the TB on your 2015 Jetta, you can do this.

Just work super-clean and have a good mirror and lighting available so you can check the back and underside positioning of the head seal before tightening the head back down.
 

JDSwan87

Black Swamp Thing
Joined
Feb 9, 2014
Location
Michigan near Toledo
TDI
2001 Jetta TDI, 5 speed Lagoon Blue Metallic(sold); 2005 Jetta TDI Wagon auto
I'd reseal the 10mm IP before swapping on an 11mm. 20min job to reseal vs an hours job to swap IP's.
 

Twinkieflyer

Well-known member
Joined
Nov 14, 2017
Location
Blacksburg, Virginia
TDI
2002 ALH 5spd
Thanks for the suggestions guys. I think I will buy the new cable and software. I have two ecu's for the 2002 so that will burn all 3 uses. considering 10 just in case a friend needs help. The reseal didn't look too bad, but will make sure I have an inspection mirror handy.
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
You could find a used "legacy" Ross Tech dongle for sale, like the Hex USB, for under $100, and the full Vag Com software will be free, plus unlimited VINs.
 

Genesis

Top Post Dawg
Joined
Feb 26, 2003
Location
Sevier County TN
TDI
'03 Jetta Wagon
I am a BIG fan of removing the pump to do this sort of job. Yes you can do the head in the car, but if you get any sort of gunk in there you can wreck the pump, the injectors -- or both. It takes very little trash to hang an injector pin and then you're doing even more work.

Cleanliness is literally God doing this sort of job and its hard to maintain that in the car. Not impossible, mind you, but difficult.

IMHO VCDS is simply necessary to properly work on and troubleshoot these vehicles.
 

JDSwan87

Black Swamp Thing
Joined
Feb 9, 2014
Location
Michigan near Toledo
TDI
2001 Jetta TDI, 5 speed Lagoon Blue Metallic(sold); 2005 Jetta TDI Wagon auto
I am a BIG fan of removing the pump to do this sort of job. Yes you can do the head in the car, but if you get any sort of gunk in there you can wreck the pump, the injectors -- or both. It takes very little trash to hang an injector pin and then you're doing even more work.

Cleanliness is literally God doing this sort of job and its hard to maintain that in the car. Not impossible, mind you, but difficult.

IMHO VCDS is simply necessary to properly work on and troubleshoot these vehicles.
While I agree with cleanliness being important, I've done 2 on-car IP reseals without issue. Special socket, regular socket, brake cleaner, tooth brush, scotch brite, file, nitrile gloves, Vaseline and patience.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
Thanks for the suggestions guys. I think I will buy the new cable and software. I have two ecu's for the 2002 so that will burn all 3 uses. considering 10 just in case a friend needs help. The reseal didn't look too bad, but will make sure I have an inspection mirror handy.
You don’t need to register any VINs in the software to do the timing and stuff. You can do a ton of stuff with it without using up your VIN allocations actually, just get the 3 VIN.
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
Yeah - I'm pretty sure you can "READ" all you like (fault codes, measuring blocks, etc.) with as many cars as you want, but only "WRITE" (coding, adaptations) to three VINs. I think that was the distinction, but it's been a while since I dug into it.
 

JDSwan87

Black Swamp Thing
Joined
Feb 9, 2014
Location
Michigan near Toledo
TDI
2001 Jetta TDI, 5 speed Lagoon Blue Metallic(sold); 2005 Jetta TDI Wagon auto
Yeah - I'm pretty sure you can "READ" all you like (fault codes, measuring blocks, etc.) with as many cars as you want, but only "WRITE" (coding, adaptations) to three VINs. I think that was the distinction, but it's been a while since I dug into it.
True statement
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
Technically it says basic settings is VIN restricted but I don’t remember ever putting my VIN in... or does it do it automatically?Anyway, here’s the info, and important to note you can upgrade a 3 VIN to 10 later on if you want:
 

Twinkieflyer

Well-known member
Joined
Nov 14, 2017
Location
Blacksburg, Virginia
TDI
2002 ALH 5spd
Thanks for everything guys. I wasn't able to get much with the unregistered version and gave up. I ordered the 10 vin one because I think I will run into friends around here that need help and I haven't been able to find a competent shop. I am waiting for it to come in so I can do the job and review the videos at least once more. Plan to really scrub the dirt off and put plastic around so I don't get crap in the pump.
I still wish there was a good shop here. The shop that told me to pickup my 2015 when it needed the belt and water pump inspected it the other day, and they asked me who did the timing belt and pump. When I told them I did it so I didn't have to trailer the car to Richmond, they asked me if I would do one for them! I declined but obviously its not happening there. I really like both of the VW TDIs but I am coming to realize I just have to do this stuff myself. The help of all of those on the forum has been great.
 

STDOUBT

Veteran Member
Joined
Jul 30, 2007
Location
Portland, effing Oregon
TDI
dos jettas
Make sure as you go to protect the pump's plastics from Diesel.
For sure when you're done make sure they're all clean. A mild de-greaser then water rinse works well.
Pic shows one "hidden" area (that wire jacket) that can get fouled and kill the conductors inside. Clean it!
 
Last edited:

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
I don’t remember ever putting my VIN in... or does it do it automatically?
Negative. I just checked and I’m still at 0/3 VINs used, and I’ve checked and done a bunch of stuff with mine and at least four other friend’s cars with it (This is my HEX-V2 btw.)
Anyway, pardon the little interruption there.
 

GlowBugTDI

Veteran Member
Joined
Jul 20, 2018
Location
Cambridge, MN
TDI
2001 Beetle GLS TDI (BIODSL). 01 original Glow Bug TDI (sold)
Negative. I just checked and I’m still at 0/3 VINs used, and I’ve checked and done a bunch of stuff with mine and at least four other friend’s cars with it (This is my HEX-V2 btw.)
Anyway, pardon the little interruption there.
Honestly never knew this! I thought it was 3 cars you could use it on. Now I kind of wish I just got a 3vin cable that I could someday use on newer tdi's. Though I'll probably be drving mk4's for another decade.
 
Top