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.
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 Leaky Injection Pump: Healing With B99 Biodiesel
Dr. Dan of Dr. Dan's Biodiesel takes us through the steps of curing a leaky
injection pump in a Volkswagen TDI. Injection pumps on TDIs and older
diesels are prone to leaks due to ultra-low-sulfur diesel fuel (ULSD) --
NOT due to biodiesel!! When a pump is introduced to ULSD and begins to
leak, an infusion of biodiesel often works to seal it up again. Dan
demonstrates the process of taking a 2000 Golf TDI ALH that is leaking ULSD
and stopping the leak with B99.
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