Pump-Injector Unit, Checking

Pump-Injector Unit, Checking

Only vehicles with engine code BEW

Recommended special tools and equipment
- V.A.G1526 multimeter or V.A.G1715 multimeter
- V.A.G1594 connector test kit
- Wiring diagram

Test requirements







- The respective fuses of Diesel-Direct fuel injection system must be OK
- Battery voltage must be at least 11.5 volts.

Test sequence
- Disconnect harness connector for Pump-Injector Unit from cylinder head.







- Check resistance of Pump-Injector Unit valves between connector terminals.

Cyl. 1: Terminals 7 + 5
Cyl. 2: Terminals 7 + 3
Cyl. 3: Terminals 7 + 2
Cyl. 4: Terminals 7 + 6
Specified value: 0.1 to 1.0 Ohms

- Check wires for short circuit to each other as well as to vehicle Ground (GND).
Specified value: Infinite Ohms

If specified value is obtained:
- Check wires to control module according to wiring diagram.

If specified value is not obtained:
- Remove upper toothed belt guard and cylinder head cover.
- Pry off connectors of all 4 pump-injector units using a screwdriver. In order to avoid canting, support opposite side of connector with light finger pressure.







- Check resistance of Pump-Injector Unit valves between connector terminals at Pump-Injector Unit valves.
Specified value: approx. 0.5 Ohms

If specified value is not obtained:
- Replace malfunctioning Valve for pump/injector, cylinder 1 -N240- to Valve for pump/injector, cylinder 4 -N243-.
- Erase DTC memory of control module for Diesel-Direct fuel injection system, Diagnostic mode 4: Reset/erase diagnostic data. Diagnostic Mode 4: Reset/Erase Diagnostic Data
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes

If specified value is obtained:







- Check wires between harness connector for Pump-Injector Unit and all 4 connectors (terminal 2) for open circuit.

Cyl. 1: Terminal 2 (gray) + terminal 5
Cyl. 2: Terminal 2 (red) + terminal 3
Cyl. 3: Terminal 2 (yellow) + terminal 2
Cyl. 4: Terminal 2 (white) + terminal 6
Wire resistance: max. 1.5 Ohms

- Check wires between harness connector for Pump-Injector Unit and all 4 connectors (terminal 1) for open circuit.
Terminal 1 (brown) + terminal 7
Wire resistance: max. 1.5 Ohms

- Check wires for short circuit to each other.
Specified value: Infinite Ohms

Check wires to control module
- Connect test box to control module wiring harness, connect test box for wiring test.
- Connect adapter cable (V.A.G 1598/39-1) to test box (V.A.G 1598/42).







- Check for open circuits in wires between test box and connector according to wiring diagram.

Terminal 2 + socket 47
Terminal 3 + socket 1
Terminal 5 + socket 46
Terminal 6 + socket 48
Terminal 7 + socket 31
Wire resistance: max. 1.5 Ohms

- Check wires for short circuit to each other, to vehicle Ground (GND) and to B+.
Specified value: Infinite Ohms

If no malfunctions are found in wires:
- Replace Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248-.
- Erase DTC memory of control module for Diesel-Direct fuel injection system, Diagnostic mode 4: Reset/erase diagnostic data. Diagnostic Mode 4: Reset/Erase Diagnostic Data
- Generate readiness code. Monitors, Trips, Drive Cycles and Readiness Codes.