ALH TDI injector nozzle swap. Setting 1st + 2nd pressures
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- Опубликовано: 25 сен 2021
- Quick video on nozzle swapping ALH TDI injectors, as well as checking first (pilot injection) and second (main) stage pressures.
Believe the lower main injection pressure in the video was from removing the lip on the top hat causing less spring pre-load on the main spring. 
Авто/Мото
First time I have seen a video of the old guy with this top hat modification.. couldn't for the life of me figure out what he did to the piece video to blurry.. thanks 😊
Btw those nozzles are worn, just like my 50 other injectors I got on the shelf.
I didn’t think you had to do all of this just to do the nozzles but I completely understand why. One of my customers got a couple bad sets of injectors that had nozzles installed on them and now I understand why, the company for sure just slammed on the nozzles.
Pop testing would be the bare minimum I’d do, they should be flow tested as well in a perfect world. Atleast with popping them you know the patterns good and they should be in time with each other.
Interesting Josh,have 3 alhs one tuned standard and 2 autos,doing tuning on all of them as I speak.
It’s not exactly the most correct way of swapping nozzles but atleast you know they’re all at the same pressures and not dribbling
bro you're a boss. thanks.
Please help me, what's the size of regulation washer? Inner diameter etc.
So sanding the top hat increases the popping pressure? Glad I found this.
yes/no, sanding the lip off the top hat increases popping pressure by making it a single stage injector vs the 2 stage which it is from the factory. The only reason i sanded the top hat in the video was to make a fixed "tool" for checking the 2nd stage pressure in this set.
So is that leakage what causes smoke on cold start ? Say after the car has been sitting overnight . Curious , I have an ALH with about 230k on the clock and I get a puff of white smoke first thing in the morning then it clears up and won't happen again for the rest of the day .
Yeah it could be time for nozzles, a little puff isn’t abnormal though. Cylinder temps are cold you’ll have poor combustion.
I have 190/300 bar and 0.360 and what is difference beetween 220/300 in full throtle? Or performnce, will nozzle work on 300 bar or ?
The lower first stage will mean the pilot injection will start a touch sooner
Where do you get shims for these injectors?
I haven't found a source but haven't looked too hard, if they're decent nozzles and all the bodies are from the same engine I cant see them being too far out
Is this all necessary? I mean for the poor man injector install. I just bought nozzles and have a really really hard time justifying paying almost as much to balance them as they cost.
I know what you man, I believe this is a middle ground between the swap-n-pray and getting them professionally balanced. This way you can check to ensure all pop at the same time (meaning start of injection is the same) and ensure no streaming/leaking nozzles. A pop tester is $100 which atleast gives you a rough idea on how they perform.
I have a question
Sure what is it
if you push till 300 bar injectors, bosch pump can not make thet pressure diesel engine can not work good, hard starting etc , just for all fox on Autodata there you have 170/190 injectors opening pressure !
good video for me but after a hour thinking about it you just ruined a injector with that mod... correctly you have to adjust only the upper shim to change your initial injection otherwise you are only engaging main injection....
I guess I didn’t explain it the greatest in the video, to be able to check the main/2nd stage pop pressure it requires a special top hat, instead of buying that tool I took a scrap injector (leak off line broken off) and modified that top hat to look like that tool.
So now you can check leakage and 1st stage with the factory top hat, disassemble and install the modified one to check the 2nd stage, then disassemble and install the factory top hat back in. It’s not meant to be ran in a car.
I'm from another country, despite the translation problem, I understood it, thanks for this way... greetings from Poland@@JoshsJettas