Engine MK4
From TDIClub
kleider bestellung tomtom navigator handy cars buy anal sex gallery i love lucy items in tucson az subaru de west jet flight alfex watches buy stocks better business bureau china massage duesseldorf 50cc scooters female art models radio cd player v710 motorola verizon outlook email setup euro pro ironing board erotic sexy lingerie public schools v3 motorola game african senegal parrots scary movie 4 uk rating washington mutual bank home page bleeding cherries popped dolce gabbana night day silver enlarge image site thumbnail web urdu font for windows schufafrei ohne sicherheit viaggi treno milano parigi frisur bild seafood restaurant stays in mexico - toby keith fine naked black women arrhythmia heart symptom vremena goda home in new rock round texas when will i find love lyrics beyonce knowles gallery mushroom name scientific captian stabbin 2006 jamaica miss world basiszinssatz der bundesbank christian teachings in modern society bitter shamesless channel 4 mainboard compaq audio city of denver co celebrity porno personal bank checks studying the book of revelations madeline fleece coat amazon warrior women lexmark cartridges texas drivers license the modern age tabs vail skiing experience web development contractor zoloft side effects valance s200 software download bucket truck sales soldiers galleries lolita web site design improve your vertical leap mexican sex helene fischer fake dermatomes total video converter cd key add album link review suggest paris musee luxembourg metra chicago schedle encyclopedia herb herb index locator matic modern o wartung reparatur service beratung ray skillman mitsubishi drop column guia de isora parenthood unconstitutional silver necklace land rover age of mithology download theatre masks antitrust legal dictionary earth map thailand jayco tent trailers delta airline flight schedule penises make a multi user dungeon free computer games ipod photo zales clearance legal aid society hawaii mexican gender roles country hotels golf usa fedex cup serena williams topless nackte asia girl by email celtic jewelry knot love Links to various MkIV Engine & Exhaust information pages
Contents |
Air Intake
- Cold Air Intake Information
--In our TDI, a cold air intake is a factory installed part that is routed around the battery box into the airfilter box. The compression of the incoming air by the turbo heats the air and then it is cooled closer to ambient air tempertures by the intercooler before it gets to the head. Some users have upgraded their intercoolers to further lower the incoming air temperature.
- Air filter information
Coolant
- Type of coolant: VW G12 (pink) or G12+ (purple). Mix with distilled water according to directions. Do not mix with other types of coolant.
- TDI Heater
EGR System (Exhaust Gas Recirculation)
- What is the EGR?
EGR is Exhaust Gas Recirculation. The intent is to 'recycle' some of the exhaust fumes back into the intake manifold to reduce peak combustion temparature.
- Problems with EGR
Some of the "watercooled EGR" systems have been known to leak antifreeze internally. If you are losing antifreeze and can't figure out where it is going, suspect your "watercooled EGR". The EGR function is also known to contribute to the dreaded "plugged intake manifold" syndrome.
- Removing the EGR
Illegal and perhaps not approprate to discuss here.
Exhaust Information
- Muffler-ectomy
- Downpipe Information
- Exhaust Tips
Glow Plugs
- Glow Plug information
Oil
(**VE engine type only**! If you have a MkIV with a PD engine, see this page)
- Types of Oil
* VW recommendation for 1996-2003 TDI engines in the US (VE type):
* SAE 5W-40
* VW 505.00, ACEA B3 or B4, or API CF-4 or CG-4. Note that API CF is not the same as API CF-4 and does not by itself does not fulfill the spec requirement. The more recent API CH-4 and CI-4 ratings do fulfill API CF-4 and CG-4.
* Example oils:
* Castrol Syntec 5W-40 / VW part number ZVW-352-540S (VW 505.00, ACEA B3, B4)
* Castrol TXT 505.01 / VW part number G-052-167-A2 (VW 505.00, ACEA B3)
* Valvoline Synpower 5W-40 (VW 505.00, ACEA B3 and B4)
* Mobil 1 Turbo Diesel Truck 5W-40 (API CI-4)
* Mobil Delvac 1 5W-40 (API CI-4)
* Shell Rotella T Synthetic 5W-40 (API CI-4)
* VW recommendation for 2004-2006 TDI engines in the US (PD type):
* VW 505.01 rated oil only.
* Example oils:
* Castrol TXT 505.01 / VW part number G-052-167-A2
* Motul Specific 505.01
* Elf Excellium DID
- Oil Change Intervals
* VW recommendation for a4-platform cars with TDI engines in the US is to have the first two oil changes at 5,000 and 10,000 miles, then every 10,000 miles. More frequent changes may apply if the car is driven low mileage per year.
- Oil Filters
Turbo Information
- VNT-15 (Stock Turbo on MkIV) information
- VNT-17 Information
- KP39 Information
- Hybrid & Other Turbo information
- Boost Valve Installation & Information
- Boost Gauge Installation & Information
Timing Belt
The ALH engine used several different combinations of timing belt components:
- 1998-2001: "old" timing belt components. Change interval is 60,000 miles for manual transmission, 40,000 miles for automatic transmission.
- 2002: "new" timing belt and tensioner. Change interval is 80,000 miles.
- 2003: "new" timing belt and tensioner, and a larger roller. Change interval is 100,000 miles.
Some late 2001 cars (with engine numbers > 500,000) came with the 2002 components, although their manuals were the same as those that came with early 2001 cars with the "old" components.
NOTE: the 2001 manuals had an error that listed the 60,000 mile timing belt change for the automatic transmission instead of the manual transmission.
Normal practice for dealers is to use the same type of timing belt components that came with the car from the factory, based on engine number. Do-it-yourselfers and timing belt gurus on TDIClub have found that the 2003 timing belt components can be used on older cars, and several parts retailers offer "100,000 mile timing belt kits".
Injection Pump (IP)
The US version of the ALH engine is shipped with two different Injection Pumps.
- The manual 5 speed transmission vehicles are shipped with a 10mm injection pump and .184 nozzles.
- The automatic transmission vehicles are shipped with an 11mm injection pump and .157 nozzles.
The 11mm IP is more desirable, because it can deliver more fuel per cycle and is especially helpful to heavily modified cars that require substantially more fuel than stock cars. Cars typically outfitted with Kerma's PowerPlus 520 Injectors and a tuning chip would benefit the most from an 11mm pump.
Alternately, an In-tank lift pump can be installed to aid the 10mm (and also the 11mm!) pumps in delivering fuel to the injectors. The in-tank lift pump may also increase the life of your IP, since the IP will not have to work as hard to draw fuel out of the fuel tank. However, the in-tank lift pump does not provide nearly as much benefit as the injection pump... but the in-tank lift pump is substantially cheaper. Having both is recommended, if money is not an object.
Injection Quantity adjusting on the IP can be achieved in two ways. One is done via the ECU with the VAG-COM software... however this method offerers only limited ability to change your IQ, and if your IQ needs to be adjusted outside of the range that VAG-COM can adjust, then you must make static adjustments on the Injection Pump itself.
The most common and easiest method of making small(er) static IQ adjustments on the IP is to do what is called a "Hammer Mod".
Timing adjustments are achieved by loosening three bolts on the IP wheel that is connected to to the serpentine belt. The wheel is rotated either forward or backwards in very, VERY slight amounts to advance or retard the timing. Timing is generally recommended to be at the top of the timing chat in VAG-COM, which is also known as advanced timing. This will generally provide better fuel economy and response.
