What did you do to your MKIV today?

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l ā€œJediā€
They are almost certainly gummed up inside. Take them out and soak them in diesel purge for a few more years then try again 😲
I realize they shouldnt be stored dry like that but he said he's not getting fuel spraying out of the lines with the nuts loose, how does that correlate? Whether the nozzles are gummed up or not there still should be fuel spraying when you crack the nuts.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
I realize they shouldnt be stored dry like that but he said he's not getting fuel spraying out of the lines with the nuts loose, how does that correlate? Whether the nozzles are gummed up or not there still should be fuel spraying when you crack the nuts.
Agreed - but it doesn't really correlate with an injector swap either, pump should not have lost prime.

My point was that persisting with improperly stored injectors will probably be an exercise in frustration.
 

northern diesel

Veteran Member
Joined
Dec 5, 2023
Location
Northern BC
TDI
2006 mk4 TDI Jetta Wagon



I picked the beetle up.
The drivers side door and the front frame horn are bent, and the engine mount is broken. The engine is going into my sister's Jetta, but I'm undecided on fixing up this beetle or parting the rest of it out.
It has no rust, which is a big plus, and the white bug is just simply a nice look, but I am not sure whether I should add to my list of things to do...
Those full moons are siiiick!!!
 

hans_gruber0

Active member
Joined
Jul 14, 2021
Location
Sierra Foothills
TDI
03' ALH wagon 5 speed
Day #2
Reinstalled dlc1019 injectors and replaced the return lines that go between them in case theres air there and still cant get a spray out of the injector nuts after sucking 1-2L of fuel from the pump
Yes some have. I have heard they are power tdi injectors they just sell. I have a set of .260s from them ( powertdi Poland) with a burpod tune and that is the combo! Had them in for a month less a day and not a single problem with the injectors once I got them seated. It runs like a dream and it pretty quick to boot.
Beginning to think I should order a set and leave them in and installed for the life of the engine
Swap injectors 1 & 2
Start the engine, let it run until it runs on all 4 cylinders (usually just a few seconds)
Stop the engine
Swap injectors 3 & 4
Move on with your life :)

No excessive cranking, no leaking diesel all over the front of the engine, no fuel spurting, no lift pump required
What do you mean by swap? Moving each injector to the one next to it?
 

skyking1

Veteran Member
Joined
Aug 10, 2013
Location
Washington
TDI
2003 beetle 2002 beetle
I have the beetle up on the neighbor's lift and it is coming apart nicely for a 21 year old rig. I have all weekend but the airbags are not here, so I will get the brakes and struts etc refreshed and roll it out until the bags come.
 

CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)
Day #2
Reinstalled dlc1019 injectors and replaced the return lines that go between them in case theres air there and still cant get a spray out of the injector nuts after sucking 1-2L of fuel from the pump

Beginning to think I should order a set and leave them in and installed for the life of the engine

What do you mean by swap? Moving each injector to the one next to it?
Change injector 1 and 2 start the car till it idles nicely and then change 3 and 4. Yes .260s with a burpod tune is well worth it.
 

hans_gruber0

Active member
Joined
Jul 14, 2021
Location
Sierra Foothills
TDI
03' ALH wagon 5 speed
Looks like maybe part of the issue was trying to restart with dlc1019's on pp764 tune. Once I changed that and bypassed the fuel filter with a jug of fuel gravity feeding the IP the car fired right up with all 4 fittings cracked open.

This is initially why I wanted to play around with the other set of injectors that had bigger nozzles:


Even the 300k+ mi fully stock poorly maintained ALH golf I hooked VCDS to had very consistent values across the board under block 013

I feel like I did a good job cleaning out the bores where the injectors and washers seat (used new crush washers and torqued them to 15 ft lb then tapped hold down bolts with punch and retorqued to the same reading to seat the washers) but the IQ deviation remains
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
I feel like I did a good job cleaning out the bores where the injectors and washers seat (used new crush washers and torqued them to 15 ft lb then tapped hold down bolts with punch and retorqued to the same reading to seat the washers) but the IQ deviation remains
You need to tap the injectors to seat the crush washers. Use a slide hammer or thread on a nut and hammer on that. Then torque the hold down and repeat until the bolts don't turn further.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
just check with soapy water or something to see if it's actually leaking. the IQ deviation is likely from something else. personally, ive never "seated" an injector and never had one leak...
 

CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)
You need to tap the injectors to seat the crush washers. Use a slide hammer or thread on a nut and hammer on that. Then torque the hold down and repeat until the bolts don't turn further.
I had one leaking and did this and it fixed it. It worked but I found when I did it to the others I couldn’t really get them to tighten anymore after tapping them so I see both sides of the coin here. As it was explained to me by burpod usually injection deviation is caused by warn out cam in the injection pump
 

hans_gruber0

Active member
Joined
Jul 14, 2021
Location
Sierra Foothills
TDI
03' ALH wagon 5 speed
Okay so no slidehammer but I can take an injector to the hardware store and see what size nut fits unless someone knows it off the top of their head.

Just worried about any potential engine damage the injector imbalance can have/has had over the past 25k+ miles
Already have what looks like soot in the coolant ball :/
just check with soapy water or something to see if it's actually leaking. the IQ deviation is likely from something else. personally, ive never "seated" an injector and never had one leak...
Usually there's a leak either at the fitting or from the bore after changing injectors in my experience but not this time for once
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
personally, ive never "seated" an injector and never had one leak...
I do it because they are crush washers and I always get at least another 3/4 turn of the bolt when I re-torque after seating.
@Franko6 and DBW had a heated disagreement about it years ago, I'm in Frank's camp ;)

 

CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)
I do it because they are crush washers and I always get at least another 3/4 turn of the bolt when I re-torque after seating.
@Franko6 and DBW had a heated disagreement about it years ago, I'm in Frank's camp ;)

I can’t see tapping on them wrecking anything or being a fireable offence and it helped in my case but maybe mine weren’t 110% cleaned up either. My cylinder head has also done 456k Km before the new injectors so maybe they just don’t seat as well. And frank0 has a good point about not tightening the crap out of the hold down bolts which this helps with. I think tap or no tap is ok. First time I pulled one out to check if it has stock nozzles I just tossed it back in with a clean and no tap and it didn’t leak. When I did the .260’s I tapped and the one still leaked a bit, one more little tap and it was fixed. Jude’s method also will work if you are gentle and careful.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
Okay so no slidehammer but I can take an injector to the hardware store and see what size nut fits unless someone knows it off the top of their head.

Just worried about any potential engine damage the injector imbalance can have/has had over the past 25k+ miles
Already have what looks like soot in the coolant ball :/

Usually there's a leak either at the fitting or from the bore after changing injectors in my experience but not this time for once
i think only damage will occur if injector has a very poor spray pattern/streaming which you'd need a pop tester to check for. the deviation numbers you see aren't horrible, but they would give pause for concern. i also don't really put a huge amount of stock in those numbers unless they are very far off. i do recall seeing one person who had numbers that weren't all that bad (Similar to yours iirc) but when he took the injectors out, there was one injector hole that was clearly globbed up like it wasn't spraying right at all - which is definitely not good at all. does it idle smoothly?

soot in the coolant ball would most certainly be from something else - leaking HG of course which most surely be from other factors like too much boost/advance combined with too much fuel/high PCPs...
 

hans_gruber0

Active member
Joined
Jul 14, 2021
Location
Sierra Foothills
TDI
03' ALH wagon 5 speed
i think only damage will occur if injector has a very poor spray pattern/streaming which you'd need a pop tester to check for. the deviation numbers you see aren't horrible, but they would give pause for concern. i also don't really put a huge amount of stock in those numbers unless they are very far off. i do recall seeing one person who had numbers that weren't all that bad (Similar to yours iirc) but when he took the injectors out, there was one injector hole that was clearly globbed up like it wasn't spraying right at all - which is definitely not good at all. does it idle smoothly?

soot in the coolant ball would most certainly be from something else - leaking HG of course which most surely be from other factors like too much boost/advance combined with too much fuel/high PCPs...
I'd have to take a video to really say. Not sure what is normal to hear or not.

I've got about ~50k mi on the last timing belt job and not very comfortable pulling the head and reassembling/redoing timing. Wish I had another mk4 to practice on or could find an ALH under $1500

EDIT: a quick video hopefully captures accurately how the car sounds https://streamable.com/rnnjtw
 
Last edited:

wonneber

Top Post Dawg
Joined
Oct 12, 2011
Location
Monroe, NY, USA
TDI
2014 Jetta Sportwagon,2003 Jetta 261K Sold but not forgotten
Well, it's a good idea to print off the pages you need before starting a job anyway, and that still applies to the paper manuals too. I'd say scan the ones you need and print em because you don't want to get grease on those books.
Having the on line manual is easier to print only the pages you need.
If the printer can print both sides (duplex) you can save the pages, hole punch them and put them in a binder.
Also my Windows 11 PC's have a print to PDF if I need to save just a section to disk.
 

hans_gruber0

Active member
Joined
Jul 14, 2021
Location
Sierra Foothills
TDI
03' ALH wagon 5 speed
I'm probably wrong but I think I'm hearing a compression leak on one cylinder. Have you squirted a little soapy water onto the injector bases and checked for bubbling ?
Thought there was something slightly tapping/knocking that wasn't supposed to be there :/

I sprayed simple green throughout the engine bay to try and clean up the fuel and didn't notice any but I can do it again.
Best done when the engine is still cool?

I also threaded a nut on and lightly tapped with a 3lb hammer to seat the injectors. No change in injector balance
 

JDSwan87

Black Swamp Thing
Joined
Feb 9, 2014
Location
Michigan near Toledo
TDI
2001 Jetta TDI, 5 speed Lagoon Blue Metallic(sold); 2005 Jetta TDI Wagon auto
Over the last few weeks...
NewSouth boost gauge
NewSouth EGT gauge (just wired up, no probe til bigger turbo)
Oil change
Gearbox oil change
.260 injectors (swapped to D plug)
.681 5th gear swap
 

ekincaid

Veteran Member
Joined
Jun 28, 2013
Location
North Carolina
TDI
03 Golf TDI
I have been replacing the serpentine belt and some hoses while looking for boost leaks. Noticed the tensioner needed replaced. The last guy who did this left the longer of the 3 13mm bolts out. Anyone know how long it is? I need to find/get a replacement.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
I have been replacing the serpentine belt and some hoses while looking for boost leaks. Noticed the tensioner needed replaced. The last guy who did this left the longer of the 3 13mm bolts out. Anyone know how long it is? I need to find/get a replacement.

I think that's the right bolt. Based on measuring the tensioner it should be 20mm longer than the other two.
 

Fix_Until_Broke

Top Post Dawg
Joined
Aug 8, 2004
Location
Menomonee Falls, Wisconsin, USA
TDI
03 Jetta
I believe it's M14x1.5 and you can use a lugnut to screw on the end of the injector. Be sure to keep it clean!!!

Another way is to use a punch between the hold down bolt and the injector and give it a good whack with a hammer
Another way is to use a hex key and an extension on the hold down bolt itself and give it a firm hit with a hammer, then re-torque

A spray bottle with soapy water is helpful to find the leaks.
 
Top