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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old January 29th, 2011, 08:45   #1
Franko6
 
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Default Simplified Setting of PD Injector Lash

The Bentley book gives a complicated and problematic method for setting the PD injector clearances. The method is to use a dial indicator mounted onto the rocker, then rotate the engine until the full depth of the stroke is reached. Screw in the adjustor screw until it bottoms out. Then back it out 180 degrees. Tighten the ball screw lock nut to 24 ft lbs. VW did standardize the setting for all PD motors for a 180 degree setting.

The problem is, there is no decent place to attach a dial indicator's bolt-on or magnetic mount.

The following pictures show how to do the operation with no dial indicator.

this is the position of the cam with the #4 injector rocker fully depressed, side and top view:



The injector is pressed to full depth when the top of the INTAKE valve cam lobe is aligned with the center of the injector lobe roller. Note that for each cylinder, the intake lobes are located across the head e-i-e-i-i-e-i-e (i=intake, e=exhaust)

This makes adjusting the injectors a very simple 'eyeball' method.
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Last edited by Franko6; October 14th, 2012 at 09:47.
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Old January 29th, 2011, 12:35   #2
PDJetta
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Thanks Frank! I like that. Nice and easy.

Bentley shows a special VW tool that bolts onto the cylinder head using a valve cover bolt hole to hold the dial indicator and I was hoping a universal dial indicator holder would do, but I have no idea on how to attach it.

--Nate
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Old February 24th, 2011, 14:04   #3
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Frank I was wondering if you could send me those pics, I'm unable to enlarge them the site say I must register

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Old February 24th, 2011, 14:28   #4
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You have to log in to the tdiclub picture gallery with your current username/password.
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Old February 24th, 2011, 18:50   #5
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Thanks turbocharger I see how to do it now, thanks also Frank nice pics
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Old February 24th, 2011, 19:04   #6
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Yeah, I got a real kick out of the Bentley procedure. Dial indicator lol. That thing is at a low spot for so long a 5yr old could set the cam correctly!
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Old April 18th, 2011, 06:43   #7
Henrick
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Any ideas on how much of resistance there should be when turning the adjusting screw clockwise, before the backing off? I mean, how tight should it be? How do I know it's enough?
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Old April 18th, 2011, 22:31   #8
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Quote:
Originally Posted by Farfromovin View Post
Yeah, I got a real kick out of the Bentley procedure. Dial indicator lol. That thing is at a low spot for so long a 5yr old could set the cam correctly!
No kidding!
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Old April 18th, 2011, 22:32   #9
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Quote:
Originally Posted by Henrick View Post
Any ideas on how much of resistance there should be when turning the adjusting screw clockwise, before the backing off? I mean, how tight should it be? How do I know it's enough?
You'll know when it bottoms out.
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Old July 4th, 2011, 04:41   #10
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I've seen guys over-tighten the ball screw. Loosen the set nut and turn the ball screw until you feel a change in resistance. Don't force it. Then back the screw off 180 degrees. Lock the set nut to 24 ft lbs.
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Old January 30th, 2012, 11:46   #11
rick.johnson0330
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Default tdi 130 injector adjustment

can i ask how often should this adjustment on the injectors be done, my golf has done 120k as far as i know its never been done
thanks
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Old January 30th, 2012, 21:15   #12
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Old January 30th, 2012, 22:09   #13
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Quote:
Originally Posted by rick.johnson0330 View Post
can i ask how often should this adjustment on the injectors be done, my golf has done 120k as far as i know its never been done
thanks
You only need to do it if you remove/change injectors.
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Old April 5th, 2012, 05:41   #14
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Apologies for thread revival...

i'm going to be doing this procedure on my mk5 as it wasnt done when we changed the injectors 22,000 miles ago and i'm trying to eliminate things for my current 'best' of 43mpg (UK) motorway mileage....

am i correct in understanding the procedure is as follows:

1) remove rocker cover

2) Rotate CAM using 18mm spanner until the rear of the roller of the rocker arm is at its highest point... (thus compressing the injector the most)

3) screw the adjusting screw in all the way in until resistance is felt

4) turn the adjusting screw BACK 180 degrees

5) maintain position of adjusting screw and tighten the lock nut

6) repeat the procedure 1-5 with the other 3 injectors

i'm guessing the use of the dial gauge in the bentley manual/vw workshop manual is to ensure the rocker follower is at its highest point and the injector is compressed the most?

many thanks for any help
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Old April 5th, 2012, 06:08   #15
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Franko6: Great post!

If anyone feels better about using a dial indicator for this procedure, I have a method that doesn't require the factory tool. I put the magnet mount on the injector rocker, which is steel, and it holds itself there securely and without any wobble. I then put the tip of the indicator on the cylinder head, on the machined surface between each cylinder bank, and rotate the engine until the indicator stops. Then set the injector lash. Works every time...

-Rich
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