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TDI 101 Got a simple/basic TDI question? Are you a newbie (new to the forums). Feel free to post your question here.

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Old December 23rd, 2017, 00:45   #1
need4speed
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Default Got it started, the Jedi way. . .

If you recall, back in September, I was having overheat problems with my 2003 Jetta.

(http://forums.tdiclub.com/showthread.php?t=481319 );

After pulling the head, having .003" shaved off, putting it back on, and a few mishaps along the way, (broken exhaust stud, EGR riser bolt, super-loose nozzle on the vacuum pump had to be peened and sealed, broken brake booster line had to be replaced, lost all my ps fluid accidentally, insufficiently torqued glow-plug leaking, trapped air in injectors, dead battery) I finally managed to get it to start and run. I didn't have VCDS to dial-in the IQ, injection timing, or boost. I had to play around with the pump timing by adjusting the wheel about a dozen times by hand, and ended up leaving it quite far advanced, but I got it to fire and run. I'm seeing fuel get to all four injectors. I was kind of shocked that I got it to run, and it's not smoking at all just by dialing it in by hand, without using the computer.

Power feels about the same - runs about the same, maybe a bit more clattery sounding. But it didn't overheat this time, which made me very happy.

Of course, I don't want to sell it now.
(I'll have to see what I can get away with though).
__________________
2003 Jetta 4dr TDI.
G60/VR6 flywheel/clutch. VNT 17 retrofit.
Never. Trust. Dealers.

Last edited by need4speed; December 23rd, 2017 at 19:18.
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Old December 23rd, 2017, 06:04   #2
Mongler98
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Location: Northern MD
Fuel Economy: Race: 12mpg, Gandma:65mpg
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COOL. good job, your tdi sounds as bad if not worse than mine. so many things to fox, all the time. i know the feeling.
For the IQ, just do your hammer mod on it till it start to idle really hard. then back it off with TINY little taps, about .5MM at a time if you can until it stops or just about to stop idling harsh. Thats about 2ish and is good enough.

Did you just deck the head? You should have measured the block too if it was overheated. Well if it runs fine then well done. btw, after a few heat cycles, recheck your headstud torque. should be fine but i have had a few need a retorque after 3 or 4 heats.

Got any pictures?
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Old December 31st, 2017, 17:57   #3
need4speed
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Default

Sorry it took a while to get the pictures uploaded; I was at my mother in law's house, and "good internet connection" is not her biggest priority in life.

I tried to measure the block as best as I could, and it seemed pretty flat to me. I didn't have a good machinist's ruler though. I tried a single-cut file as suggested by Frank06, and that seemed to show a straight block.

As the motor idles, (and runs, so far) I don't think I need to adjust IQ. I'll have to see about re-torquing the head studs. When I torqued them the first time, it was a pretty cold day (by California standards, it was about 45 degrees F out). Everything I read about the subject seemed to say that as long as all the parts were the same temperature, it didn't matter. (though I still think there'd still be an elasticity difference?).

However, I do seem to be getting some smoke out of the backside somewhere, and I can't really tell if it's exhaust or if it's just oil and cleaner burnoff. (I scrubbed everything down pretty good, because it was previously an oily mess back there). The smoke was pretty visible at first, and kind of tapered off as the motor ran, so I don't think it's leaking, I tend to think it's burnoff. Anyway, it's not leaking coolant.

Here's some photos I uploaded:

The head fresh from the Harry's Power Performance in San Luis Obispo:
http://pics.tdiclub.com/showphoto.ph...40021&cat=6892

Fastener broke on EGR cooler connector to turbo, but I was able to drill it out:
http://pics.tdiclub.com/showphoto.php?photo=126127&title=20171203-160541&cat=6892

Turbo exhaust flange stud broke off as-well, with enough meat to try to cut a slot:
http://pics.tdiclub.com/showphoto.ph...63035&cat=6892

. . . . sadly, that broke off, and was very stubborn drilling out, and I damaged the threads in the attempt (and I also snapped my smaller left-hand easy-out drill bit, so thats why I went with the bigger bit):
http://pics.tdiclub.com/showphoto.ph...65446&cat=6892

Helicoil install:
http://pics.tdiclub.com/showphoto.ph...13530&cat=6892

Head back in and torqued:
http://pics.tdiclub.com/showphoto.ph...03258&cat=6892

I was not super-careful with my injectors. If I had the budget, I would have bought new 520's, and I may still do that. What I did was pull these, and wire-brushed them clean (brass, not steel), and re-installed them with fresh copper washers. These have 220,000 miles on them, so I just kind of assumed I was going to have problems. But they actually seem to work.
http://pics.tdiclub.com/showphoto.ph...22300&cat=6892

Almost completely back together:
http://pics.tdiclub.com/showphoto.ph...21041&cat=6892

I tried to upload a video to the file-sharing site, but it won't play, unfortunately.

__________________
2003 Jetta 4dr TDI.
G60/VR6 flywheel/clutch. VNT 17 retrofit.
Never. Trust. Dealers.
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