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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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May 6th, 2013, 12:08 #1

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 fierodough How to thoroughly clean ALH injectors (with steam)

Veteran Member
How to thoroughly clean ALH injectors
Join Date: Mar 2013
Location: Ontario My injectors were pretty sad to say the least. Covered in soot and no longer
TDI(s): Beetle had the proper firing pattern. My symptoms were smoke from the exhaust,
Fuel Economy: 5.7l/100km
Injector balance readings in VCDS were skewed, IQ was dropping and took
several cranks to start the engine.

What you will need:

New injector washers (4)
15mm wrench
17mm wrench
13mm socket and ratchet (and an extension)
Pliers
Steam
A diesel injector cleaner that seeks out water like Power Service grey bottle.
A steam gun (you can get this at Wal-Mart for under $50
Lots of shop towels

Sorry, I didn`t take any pictures But I will add some when I do it again.

So take your injectors out.

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1. using the 17mm wrench to loosen the fuel lines to each injector and loosen
the lines at the pump. Do not remove the lines from the pump, just keep them
loose and pull the fuel lines away from the injectors.
2. Disconnect the glow plug harness and just move it down out of the way
3. Remove the fuel return lines from the injectors.
4. Removed the injector clams (13mm socket)
5. Disconnect the No 3 injector plug.
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 5. Disconnect the No 3 injector plug.
6. Remove the injectors (mine were easy as I put anti-seize on them. You
might need to use a slide hammer or wiggle them with the 17mm wrench.

Time to disassemble the injectors and clean them:

1. Place some show towels down on a working surface. Make sure
everything is VERY clean.
2. Fill up a container with your injector cleaner
3. With the 17mm wrench, hold the injector body while undoing the top of the
injector with the 15mm wrench. They can be tight!
4. Once removed, the tip can be taken off the injector tip (be careful the
injector pin is in there) Keep the injector tip and injector pin together! Do not
mix them up!
5. Place them in the injector cleaner
6. Fill up the steam gun and let it warm up while the injector tips are sitting in
the cleaner.
7. Take out one tip and pin. Place them on the shop towel.
8. Using pliers with a bit of shop towel wrapped the claws, pick up the injector
tip from the base (not the part that the fuel fires out of)
9. Using the steam gun, spray the tip to clear the little holes.
10. Using the spray gun, spray from behind the injector tip in the needle hole
and look for a spray pattern out of the tip with the steam.
11. Repeat 9 and 10 until you are happy with the spray pattern.
12. Use the steam gun to clean the needle as well.
13. Using a shop towel , dry off the needle and tip and place them back in the
container with the injector cleaner.
14. Repeat for the next injector.

To re-install the injectors do the same as removing them but in reverse. I like
adding anti-seize to the part of the injector making contact with the head.
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 adding anti-seize to the part of the injector making contact with the head.
(none on the tip! Injector clamp bolts (13mm) are torqued to 15ft-lbs.

May 6th, 2013, 16:11 #2

AndyBees
Veteran Member
Excellent thread.

I'd suggest using compressed air at some point in the cleaning process.
__________________
'84 Vanagon '02 ALH TDI engine(32 to 35+ MPGs consiste ntly) Malone Stage 1 tune .
R oad trip to Nova Scotia 2013. R oad trip to Alask a sum m e r 2014 & 2016, 11k & 12k m ile s.
Join Date: May 2003
71k m ile s on install, Je tta C luste r odom e te r curre ntly at 200k k m ile s.
Location: Southeast
Kentucky
TDI(s): Silver 2000 Jetta TDI,
'84 Vanagon with '02 ALH
engine
Fuel Economy: life time
average above 50 MPG on the
Jetta

May 6th, 2013, 16:26 #3

1.9glstdi
Veteran Member
Join Date: Jan 2010
Location: J-vill,FL
TDI(s): 2005 4D Golf BEW PD
Fuel Economy: 37MPG
around town automatic poo
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Well what we really need to know. How does it run now? lol
__________________
2005 4dr Golf, Reflex silver,BEW PD, auto/tippy, 20% tint all around, FL plates
VR6 suspension, tt lca's
Egr blocked, Dog collar
I Have vcds KII-usb for 2005 and older
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 I Have vcds KII-usb for 2005 and older
poo

May 6th, 2013, 17:01 #4

Seatman
Veteran Member Quote:

Originally Posted by 1.9glstdi

Well what we really need to know. How does it run now? lol

It doesn't, all the parts went everywhere lol

Join Date: Apr 2010
Location: Scotland
TDI(s): Mk4 golf 1.9tdi AJM
Fuel Economy: No idea

May 6th, 2013, 20:57 #5

nathan_b
Veteran Member Quote:

Join Date: Oct 2012 Originally Posted by Seatman

Location: athens ohio It doesn't, all the parts went everywhere lol
TDI(s): 1999.5 alh jetta/
2002 alh jetta
Fuel Economy: 50mpg good one haha

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 May 6th, 2013, 21:52
1.9glstdi
Veteran Member
Join Date: Jan 2010
Location: J-vill,FL
TDI(s): 2005 4D Golf BEW PD
Fuel Economy: 37MPG
around town automatic poo
poo
May 7th, 2013, 02:33
fierodough
Veteran Member
Join Date: Mar 2013
Location: Ontario
TDI(s): Beetle
Fuel Economy: 5.7l/100km
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#6
XD you guys.
__________________
2005 4dr Golf, Reflex silver,BEW PD, auto/tippy, 20% tint all around, FL plates
VR6 suspension, tt lca's
Egr blocked, Dog collar
I Have vcds KII-usb for 2005 and older
#7
Quote:
Originally Posted by 1.9glstdi
Well what we really need to know. How does it run now? lol
Runs much better and starts much faster. Just cleaning my injectors took me
from IQ of 3.5 - 4.0 to 6.0
The first few times I sent pressured steam through the injector tip, I had a bad
spray pattern, on one tip I only had 3 jets working. After cleaning the tips with
the steam I was able to actually see the spray pattern and I compared it to
ALH injector spray patterns found on the internet.
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 The great part is the steam blasts through the carbon and soot but does not
harm the injector at all. Then placing it it the injector cleaner insurses there is
no corrosion.

May 7th, 2013, 02:33 #8

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 fierodough
Veteran Member Quote:

Join Date: Mar 2013 Originally Posted by Seatman

Location: Ontario It doesn't, all the parts went everywhere lol
TDI(s): Beetle
Fuel Economy: 5.7l/100km
I don't understand what you mean there?

May 7th, 2013, 04:13 #9

VWMatt
Member Quote:

Join Date: Mar 2013 Originally Posted by fierodough

Location: Pennsylvania I don't understand what you mean there?
TDI(s): 2002 Golf TDI

Seatman was trying to be funny

May 7th, 2013, 05:01 #10

fierodough
Veteran Member Quote:

Join Date: Mar 2013 Originally Posted by VWMatt

Location: Ontario Seatman was trying to be funny
TDI(s): Beetle
Fuel Economy: 5.7l/100km
Oh! My bad. I was trying to figure out how the parts would go flying all

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 over. :\

May 7th, 2013, 07:05 #11

TDI_G
Veteran Member
Can you provide a link to the steam gun you used.

Join Date: Dec 2011

Location: Sugar Hill, Georgia
TDI(s): None C urrently- 2008
BMW 335I

May 7th, 2013, 07:17 #12

fierodough
Veteran Member Quote:

Join Date: Mar 2013 Originally Posted by TDI_G

Location: Ontario Can you provide a link to the steam gun you used.
TDI(s): Beetle
Fuel Economy: 5.7l/100km

This is the one I'm using (just because i already had it at home)
shark Steam Blaster

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 They go for about $150...

But you can get away with using this:

http://www.walmart.com/ip/Steamfast-...F-210/16571806

You will get the same results. Just won't be able to clean hardwood floors with
it after. :P

May 7th, 2013, 20:24 #13

AndyBees
Veteran Member
Well, if this really works, I finally bumped into something my steamer is capable
of doing. I got mine for about $100.00 ten years ago and found it to be
useless!
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 Good find!
Join Date: May 2003 __________________
Location: Southeast '84 Vanagon '02 ALH TDI engine(32 to 35+ MPGs consiste ntly) Malone Stage 1 tune .
Kentucky R oad trip to Nova Scotia 2013. R oad trip to Alask a sum m e r 2014 & 2016, 11k & 12k m ile s.
TDI(s): Silver 2000 Jetta TDI, 71k m ile s on install, Je tta C luste r odom e te r curre ntly at 200k k m ile s.
'84 Vanagon with '02 ALH
engine
Fuel Economy: life time
average above 50 MPG on the
Jetta

May 7th, 2013, 20:39 #14

FlyTDI Guy
Veteran Member
I usually use my ultrasonic cleaner and some bio or regular D2. Only problem
was the bio turned my lid to mush. Oops... I'll have to find a better solvent in
the future.
__________________

'01 Je tta GLS, 5 sp, Black on Black , Le athe r, Sun R oof, MFSW , Monsoon, C old W e athe r Pk g.,
Join Date: Nov 2001 Full LED inte rior, always a work in progre ss
Location: PNW
TDI(s): '01 Jetta GLS
Fuel Economy: 56.5/44/41

May 8th, 2013, 12:16 #15

888
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 Veteran Member
Nice writeup! With the trouble I had getting the lines bled out after my TB
Join Date: Aug 2002
change, I'd probably be inclined to do them one at a time and fire the car up in
Location: Brookville Ohio between each of them to keep everything primed.
45309 __________________
TDI(s): 02 Golf GLS 5 speed (previously TDIRookie) 02 Golf TDI, 89, 92, and 93 Dodge Cummins trucks.

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