How to tune up your TDI
Today i show ya how to tune up your Diesel engine.
In the injector cleaning part of the video, i dont explane part one, since
its not very safe, however, you dont need to do the first stage, stage two
(boiling in the engine oil) will usually work perfect. add some off the
shelf ATF to really clean them up.
2009 VW Jetta TDI - Fuel Filter Change
Fuel Filter Replacement in a nutshell:
1) Replace every 20K miles (I do mine every 10K with oil change).
2) Have the right filter for your housing.
3) Engine OFF! Remove Upper Sound Absorber Panel.
4) Water Separator Service (1 Screw Plug, 1 Washer Seal)
a. Remove Screw Plug and old Washer Seal with Torx T30 bit.
b. Siphon water at bottom of Filter Housing from top of housing - A.K.A
c. Siphon enough fuel to avoid spillage when Housing is opened.
d. Reinstall Screw Plug with New Washer Seal. Torque 3 Nm (27 in-lb).
5) Fuel Filter Replacement (1 Filter, 2 Seals on Filter, 2 Seals in
a. Remove 5 Torx T30 Bolts and lift off Upper Filter Housing with lines
b. If you see any amount of metal particles TAKE THE CAR TO A
PROFESSIONAL! You have a major issue.
c. Pull out old Filter and Seals in Housing.
d. Clean as necessary Lower Filter Housing by Siphoning out remaining
NOTE: Removal of Lower Filter Housing is not a requirement. So long
as you remove any contaminants found at the bottom of the canister by other
e. Install New Filter and New Seals.
f. FILL CANISTER WITH CLEAN FUEL to help purge air. (approx. 650 ml or
22 oz) ---OR--- Use VAG-COM to operate fuel pump from fuel tank to prime
the fuel system (the air will be sent back to the tank to vent) SEE VAG-COM
STEP BELOW (7).
g. Reinstall Upper Filter Housing and secure with 5 Bolts. Torque 5 Nm
6) Reinstall Upper Sound Absorber Panel.
7) If you have VCDS/VAG-COM, operate fuel pumps to purge air from Filter
8) Otherwise, Start Engine & try to run it at 2K RPM for at least 30
seconds. If Engine shuts down, restart engine (this method is not
preferred. it is bad for your High Pressure Fuel Pump).
NOTE: Turning key to turn on Accessories does not turn on the fuel pumps,
from what I have read, only when the key is turned to Ignition (Engine
A visual aid to what to expect when replacing the Fuel Filter on the 2009
VW Jetta TDI (A5 - CBEA ).
I used as a reference the Bentley Publishers VW Jetta Service Manual
(2005-2010) as well as a couple of very good write-ups which can be found
at the following links. Many thanks to those who took the time to document
and share the information at these links.
I obtained the Mann Fuel Filter from IDPARTS.COM (formerly TDIPARTS.COM),
UPS Ground Shipping was free with them. Amazon.com also offers the same
Mann Fuel Filter for those who are exclusive to Amazon.
How To: Diagnose Restricted Fuel Supply on a VW TDI
One of the most common causes of starting, drivability and performance
issues in Volkswagen TDI diesels is fuel system restriction -- at the fuel
filter, at the fuel tank, or anywhere in between. Dr. Dan of Dr. Dan's
Biodiesel explains how and why this happens, and what to do about it. Fuel
system plugging is usually caused by contamination from dirty, unfiltered
diesel fuel, but biodiesel often gets the blame! Dan explains the various
causes, symptoms, and consequences of fuel supply restriction in TDIs and
takes us through the process of diagnosing and repairing a restricted fuel
system on a 2000 VW Golf ALH TDI.
VW TDI Fuel Filter Restriction: Causes, Effects, and Cures
Replacing the fuel filter on your Volkswagen TDI is one of the simplest
maintenance items you can do, but it is also one of the most crucial. Dr.
Dan of Dr. Dan's Biodiesel explains how a clogged fuel filter can cause a
multitude of symptoms, ranging from simple low power and hard starting to
more deceptive ones such as limp modes, check engine lights, turbo malfunctions, and more. Often these are
mis-diagnosed as much more serious problems when all that is needed is a
fuel filter replacement. Prolonged operation with a plugged filter can also
lead to much more serious and expensive problems. Dr. Dan discusses
diagnosis, diesel fuel quality issues and recommended sources, and takes us
through the procedure of replacing a fuel filter on a TDI vehicle.
Volkswagen Pump Timing video.wmv
Short video on how to set the injection pump timing on the Volkswagen 1.6
The Bentley service manuals list the following settings:
Early Chassis: (1977-1983)
1.5l non-turbo 1977-1980
0.88 +/- 0.05 mm
1.5l non-turbo 1980 with yellow dot
1.15 +/- 0.05 mm
1.6l non-turbo 1981, 1982, and 1983
pickup 0.88 +/- 0.05 mm
1.6l non-turbo 1983 Rabbit and Jetta
0.95 +/- 0.05 mm
1.6l non-turbo 1983 Vanagon
0.90 +/- 0.05 mm
1.6l tubo diesel (1982-1983) 1.00 +/-
MK2 / A2 chassis: (1985-1992):
Engine ME (1.6l non-turbo) 1985
0.95 +/- 0.02 mm
Engine ME (1.6l non-turbo) 1986 and up
0.90 +/- 0.02 mm
Engine MF (1.6l turbo)
1.00 +/- 0.02 mm
Engine 1V (ECO diesel) 1.00 +/- 0.02 mm
MK3 / A3 chassis (1993-1997):
Engine AAZ (1.9l turbo)
0.80 +/- 0.02 mm
VW TDI Timing Belt with no Tools + Helpful Hints
TDI Timing Belt with no Tools. 03 TDI Golf with 1.9L ALH engine. The
Timing belt broke and took 3 valves(two intake + one Exhaust), 5 Lifters(or buckets) & the vacuum
pump with it. I Used 15/64 drill bit to pin the diesel pump. Got All the
parts(timing belt kit + valves + Lifters + head rebuild kit + odds&ends)
from MetalManParts.com for about $580. I got the Vacuum pump for $190 from
MobileOneInc.com. I got 4 new OEM Glow Plugs from WWW.BoraParts.com for
$45.50. I also broke my turbo GT1749V.
I was going to rebuild it but I would have no way to balance it. If you do
not Balance your turbo it will not last
more than 1 month. That is a lot of money and effort to waste on a 1 month
turbo. I broke my turbo trying to get to the VNTs (vents) to clean
them (diesels are know for fouling the turbo VNTs). I Got GT1749V (center housing
rotating assembly) from WWW.XSBoostturbochargers.COM for only $360. The turbo comes with a VSR report and real balancing
1) Don't forget to put the lower timing belt cover back on before the motor
mount. I wasted 50 mins re-doing the motor mount because I forgot to put
the lower timing belt cover on first.
2) I use High temp RTV instead of thread lock. High temp RTV will seal out
water and remain elastic even after several heating and cooling sessions.
RTV will also stop nuts and bolts from falling out do to vibration.
3) Always check flywheel for Cyl #1 TDC
4) Don't work in the frick'n cold