TDI engine cover retainer upgrade (ALH engines to '04)

[mwilson]

Gizmo has been missing his pretty little engine cover ever since I bought him. Had checked into a replacement but was approaching $200. 00 or so.



Asked the previous owner if he might still have it last fall. The other day a VW engine cover shows up on the doorstep, HE FOUND IT!!!



The fasteners had seen better days and as I researched the replacement parts I discovered an upgrade. You remove the existing studs and replace them with a VW ball stud, enlarge the holes in the cover to accept the newer socket / grommet combo and it converts the cover to a pop off design. No tools needed to remove the cover after the upgrade.



No one seems pleased with the stud and nut set-up that came from the factory.



It only requires 2 studs and grommets to do this, the VW geeks say not to bother with the one in the rear on the intake.



Part numbers are...



06A-103-226 (2) Socket @ 6. 00 each

06A-103-951 (2) Ball Stud @ 11. 50 each



I will take pictures tonight when I install the new parts.



Mike.

 

[PMould]

mike,my 04 pd tdi bew engine has that ball and grommet set up. just pull and off it comes,neat. did you ever do the frost heater? how is the new pump working? take care of gizmo:-laf pete

 

[mwilson]

mike,my 04 pd tdi bew engine has that ball and grommet set up. just pull and off it comes,neat. did you ever do the frost heater? how is the new pump working? take care of gizmo:-laf pete

Hi Pete,



I have not purchased the frost heater yet, it actually was not that bad last winter. The thing starts great even at -20 below as long as you wait for the glow plug light to go out before cranking it. I know that I would get faster cabin heat if I install it, I am still thinking about adding it.



The pump seems to be doing great, it has about 20,000 miles on it right now. I am finding that the 10,000 miles change interval on the fuel filter is pure bull**** as I can only get about 7500 on them before it will act out. I just changed one the other day at the 7,000 mile mark. I will now change them at 5,000 miles along with the oil and filter.



Getting a very consistant 42mpg driving 73-75 mph with the A/C on. I am quite pleased with that.



Mike.

 

[GCroyle]

Mike,



What are you seeing as symptom that the fuel filter is kaput? Ever cut one open yet?



Got about 12K on mine so far, so good. Put a Westac combo gage on it.





Yeah, pics please.



Gary

 

[mwilson]

Mike,



What are you seeing as symptom that the fuel filter is kaput? Ever cut one open yet?



Got about 12K on mine so far, so good. Put a Westac combo gage on it.





Yeah, pics please.



Gary

It will either lose top end RPM's, like from 2400 up. The episode it had the other night was a bucking fit. Did it for a couple of minutes and it came out of it. Changed filter as soon as I got home, drained it first and did see some water spots.

Maybe just bad luck but am going to service it everytime from now on just to be safe.



Mike.

 

[mwilson]

Dusty Ol' Cover

Broken Stud In The Intake Manifold (A present from someone that over tightened it in the past)

Front Mounting Points

New Style Ball Stud

New Ball Studs Installed

 

[mwilson]

 

[JLEONARD]

Our TDI has not had the cover on since soon after we bought it. No plans on putting it back either.

 

[Jim W]

The pump seems to be doing great, it has about 20,000 miles on it right now. I am finding that the 10,000 miles change interval on the fuel filter is pure bull**** as I can only get about 7500 on them before it will act out. I just changed one the other day at the 7,000 mile mark. I will now change them at 5,000 miles along with the oil and filter.
Mike.

Mike it must be that MAINE diesel you are buying up there.

My wife's TDI seems to get 20k between filter changes; factory change interval. I do know that we buy 90% of our diesel fuel at one station and brand of fuel for her car. I have asked the fuel tank truck drives there and they have said that the summertime diesel is 11% bio now (IL tax incentive) and the winter fuel is straight diesel with no bio in it. This is a high volume station for both gas and diesel so the turnover rate is high for fuel usage.
Jim

 

[mwilson]

Mike it must be that MAINE diesel you are buying up there.



My wife's TDI seems to get 20k between filter changes; factory change interval. I do know that we buy 90% of our diesel fuel at one station and brand of fuel for her car. I have asked the fuel tank truck drives there and they have said that the summertime diesel is 11% bio now (IL tax incentive) and the winter fuel is straight diesel with no bio in it. This is a high volume station for both gas and diesel so the turnover rate is high for fuel usage.

Jim

It could be the fuel, although the Irving Diesel that I run always has been the best in the state.



When I brought Gizmo home he came with instructions to never fill it over 3/4 of a tank or it would "Leak"...



Well of course Seth and I had to try it... . :--)

It was fine at the fuel station after the top-off so I headed for home and parked it. The next morning I come out and under the car it looks like the Exxon Valdez had been anchored there overnight.



Took the access cover off under the back seat and discovered that the plastic threaded ring which holds the sending / fuel pick up unit in place on the fuel tank is off and hanging on the fuel lines. That would explain the leak when full... ... ...



Threads were fine, all was well. Looked in the tank for debris and it looked good. Installed the ring, tightened it and it has been leak free ever since.



Now maybe there is still some crud in the fuel tank as a result of that episode that gets sucked into the filter every now and then.



Mike.

 

[Dobrien]

I have an '02 Jetta TDI with 177,xxx miles on it. Bought it with 82,xxx. I had the 100K timing belt, new water pump, bigger injectors, oil and filter change as well as fuel filter changed when I bought it. Even though I haven't put 100K on it, I just had the 100K timing belt and new water pump put on as well as a few other things maintenanced on it. I've always changed the fuel filter every other oil change. Never had any issues with it. I mad the switch to the socket and grommet setup just after I bought the car. It looks much nicer with the cover on it and it comes off really easy when I need to do other stuff on the engine. Are any of you members of TDICLUB? Lots of good info there on the VW TDIs. I never thought of looking here (TRD) for any TDI related posts.

 

[crispyboy]

Used to own a 1997 TDI with the stud/nut setup. Pain in the butt to remove to clean an aftermarket CCV filter that I installed to catch some oil before it would get sucked back into the intake manifold.
I like the ball/socket setup.