What did you do to your MKIV today?

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,



Today I had this cream puff in the shop for a turbo and intake manifold replacement. 190k miles on the clock 5 speed manual alh.


Yep, it was about time for that...


After cleaning the egr valve. A walnut hull blaster is a very nice thing to have in the shop! One of the most often used pieces of equipment.

And then the other mk4 I had in the shop... this one on the other side of the spectrum... it was neglected, abandoned and hacked up... but it was cheap, so it should be decent after I get the hack job wiring from the manual swap fixed. Also gotta replace the parts store alternator it has in it, as well as the alternator wiring harness.
Just did the cam and timing belt.

 

CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)



Today I had this cream puff in the shop for a turbo and intake manifold replacement. 190k miles on the clock 5 speed manual alh.


Yep, it was about time for that...


After cleaning the egr valve. A walnut hull blaster is a very nice thing to have in the shop! One of the most often used pieces of equipment.

And then the other mk4 I had in the shop... this one on the other side of the spectrum... it was neglected, abandoned and hacked up... but it was cheap, so it should be decent after I get the hack job wiring from the manual swap fixed. Also gotta replace the parts store alternator it has in it, as well as the alternator wiring harness.
Just did the cam and timing belt.

That first Jetta is beautiful! Even the second one looks pretty rust free.
 

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.. :/
it's insane how anyone can let an egr clog up like that and not know. then again, i'm surprised day after day
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
That first Jetta is beautiful! Even the second one looks pretty rust free.
Yeah, its pretty decent body condition, and I got it for $500, which isn't too bad, but the wiring is a mess...
 

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.. :/
Are you surprised? Lol people are special
not really i guess. but somewhere deep in my heart i have optimism. but yet, every day i get surprised... the number of things i've seen over the last few years continues to "surprise" me. yet i still feel surprised lol
 

hans_gruber0

Active member
Joined
Jul 14, 2021
Location
Sierra Foothills
TDI
03' ALH wagon 5 speed
There was a good bit of deviation of IQ between injectors on my set of injectors with dlc1019 nozzles I'd reused crush washers on a year or two ago.

So today pulled the injectors, old washers, and cleaned the injectors bores/seats and put in a set of used pp764 nozzles/injectors I'd bought from a guru several years ago and installed them.

Pulled the injector return line fitting completely off and sucked alot of fuel with Capri tool brake bleeder and still could not get a spray or stream of fuel when cracking the injector nuts loose 4 at a time or two at a time (#1 and #3 ->> #2 and #4)

Now left scratching my head of how I got past this issue last time. Might have been a bottle of diesel purge held high above the pump feeding directly into the line that feeds the pump bypassing the fuel filter and fuel filter T all together but alas the store is closed and nobody to hold the bottle for now
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
Really hoping for an actual wiring issue, since pulling the sensor doesn't sound like fun (and neither does replacing the hub)
I'll take removing a sensor over tracking down a wiring issue on something that starts under the hood and reaches all the way to the rear wheels. Unless, of course, there's an abraded wire screaming HERE I AM as soon as I pull off the wheel. :)
 

Rob Mayercik

Veteran Member
Joined
Dec 19, 2001
Location
NJ, U.S.A.
TDI
2002 Jetta GLS, Baltic Green/Beige
Congrats on 500k miles!

How did I just find out that there is a volume 2 of the manual? Mine is a single book ~3" thick?
Thanks. From what I found, the paperback version still comes in a single volume, but the hardcover (which is what I got) got split into two books. About 3 inches does sound close to the combined thickness on these, if I account for the covers themselves.

Considering the two together weigh 11.5 pounds, it's probably for the best that they split the hardcover edition in two as it's a lot of mass to carry around, and a single book probably makes it more challenging to set it open to a particular page.

I'll take removing a sensor over tracking down a wiring issue on something that starts under the hood and reaches all the way to the rear wheels. Unless, of course, there's an abraded wire screaming HERE I AM as soon as I pull off the wheel. :)
That's generally what I'm hoping for - the replacement harnesses I see online have grommets that indicate that it goes into the body up in the wheel opening, so I'm making the assumption that once it's within the body it's fine, and the potential for damage is between the grommet and the sensor.
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,

Hmm... maybe thats part of why there isn't any boost... anybody got a good bew intercooler they don't need anymore?
I've been working through this bew. It has a cone air filter, so the maf is shot as well. Then I could hear a boost leak... yeah this would do it lol.
 

hans_gruber0

Active member
Joined
Jul 14, 2021
Location
Sierra Foothills
TDI
03' ALH wagon 5 speed
They are almost certainly gummed up inside. Take them out and soak them in diesel purge for a few more years then try again 😲
Yeah, those injectors are not in good health.
Good to know rather than just keeping on cranking. Just noticed that the shielding for the 3rd injector wire is frayed as well. Thank you
DLC1019's going back in tonight and I guess this spare pp764 set are cores

Such a chore without a lift pump!

EDIT: on an unrelated note. does anyone have experience with buying injectors from xmanturbos?
 
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CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)
Good to know rather than just keeping on cranking. Just noticed that the shielding for the 3rd injector wire is frayed as well. Thank you
DLC1019's going back in tonight and I guess this spare pp764 set are cores

Such a chore without a lift pump!

EDIT: on an unrelated note. does anyone have experience with buying injectors from xmanturbos?
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.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
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

Well-known 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
 
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