TDI Injector/Nozzle Swap Howto
This document explains injector removal, nozzle swap, and injector reinstallation on a VW TDI. The car used was a 2001 Golf (ALH engine). The instructions should be similar for earlier TDI engines (AHU and 1Z). I welcome email with comments or questions about the content of this howto!
I‘ve broken the job down into four sections: removing injectors, swapping nozzles, installing injectors, and ECU adjustments. If you just want to install new injectors and aren‘t doing a nozzle swap, just skip that part. It‘s recommended that after installing nozzles you get them pop-tested by a local Bosch shop (http://www.boschservice.com) certified on VE equipment. Any shop knowledgeable about Dodge/Cummins diesels should be able to help. They can set the spring preloads in the nozzles and make sure that the spray pattern is good. These shops can only set one of the two springs in the injector, but that‘s better than nothing.
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