Single mass clutch and flywheel kits are often the go-to replacement for older TDIs. Valeo, an OE supplier, offers a full line of custom engineered single-mass clutch conversion kits. These kits are special designed to deliver smooth operation and reliable service life. What is a Single Mass Flywheel and Clutch Conversion Kit? All TDIs from 1999 to the latest 2015 models used “dual mass” flywheels. Read more about dual-mass flywheels. Unfortunately over time these flywheels fail, often before the clutch itself is worn out, leading to a premature and expensive repair. Single-mass conversions re ..read more

Alternator amperage ratings refer to the maximum current that an alternator can produce to supply electrical power to a vehicle’s systems and recharge the battery. When replacing your alternator it is important to use one that is correctly rated for the vehicle. These ratings are important for several reasons: Key Points of Alternator Amperage Ratings: Vehicle Electrical Load: Modern vehicles have numerous electrical components such as headlights, infotainment systems with GPS, power windows, air conditioning, and more. The alternator must supply enough current to power all these systems sim ..read more

Cleaning a MAP (Manifold Absolute Pressure) sensor is a pretty straightforward task but requires some care to ensure it’s done properly, without damaging the sensor. What is Needed: MAP Sensor Cleaner: Specifically designed for cleaning sensors. Do not use other types of cleaners like carburetors or brake cleaners, as they are too caustic, and may damage the sensor. The appropriate tools to remove the MAP: Most are held in with simple phillips or torx head screws, or with small nuts or bolts. Soft brush or cloth: For gentle cleaning, either a specialty brush, or even a very soft toothbrush ..read more

Introduction When TDIs were introduced in North America in 1996, VW wasn’t especially picky about what oil they needed. That quickly changed when the engines experienced coking on the piston rings, and VW soon recommended synthetic oil meeting their 505.00 specification.  Fast forward to 2009 and the launch of common rail TDIs with diesel particulate filters (DPFs), and using the correct oil was suddenly much more important. VW says oil for most 2009 and later TDIs must meet their 507.00 specification.  In this article we’ll dig into the characteristics of oil meeting that spec, how ..read more

What does the serpentine tensioner do? The serpentine belt tensioner is a vital component of the accessory belt system. It maintains proper tension, so the belt remains tight around the pulleys it drives. The belt provides power from the crankshaft to engine accessories such as the power steering pump, the alternator, and the air conditioning compressor.  Proper tension is essential for efficient power transfer and to prevent the belt from slipping. The serpentine belt will naturally stretch over time and the tensioner can compensate for this by automatically adjusting tension to maintain ..read more

For a few years before VW adopted common-rail technology a unique “unit injector” injection system was used. Read all about VW’s experiment, which engines used it and what the problems are. Which TDIs Used the PD type Engines? VW used the PD style in TDI engines for US model years 2004-2008, including: 2004-2006 Mk4 Jetta Wagon TDI , Golf TDI and New Beetle TDI – engine code BEW 2004-2005 Mk4 Jetta TDI (Sedan)- engine code BEW 2005.5-2006 Mk5 Jetta TDI (Sedan) – engine code BRM 2004-2006 B5.5 Passat TDI – ending code BHW 2004-2008 Touareg TDI with V10 Engine – engine codes BKW & BWF What ..read more

The tandem pump on PD TDIs can leak diesel fuel into the head, causing camshaft failure. PD Camshaft Failure Background The PD family of VW TDIs is known for camshaft wear and premature camshaft failure. This can lead to a variety of issues. Read our article about PD Camshaft Failure for more information. What is the Tandem Pump? The PD engine uses a two part pump on the back of the head (drivers side on transverse engines) where typically the vacuum pump would go. This two-part pump is both a vacuum pump and a medium pressure fuel pump sandwiched together in a tandem format and therefore it i ..read more

Replacement actuators are now available for the OM642 turbocharger, but it is important to find the correct version. OM642 Turbocharger Information The Mercedes OM642 turbocharger uses variable internal vanes, also referred to as a VNT, in order to direct airflow through the turbines which increases or decreases turbocharger pressure. On the OM642 motor the vanes are controlled by an electronic servo motor bolted to the outside of the turbocharger. It is circled in the photo below. P2510 Fault Code for Component Y77/1 The P2010 code referring to component Y77/1 being faulty is an indication th ..read more

The end of an era has arrived for TDI owners and mechanics alike. For decades, paper repair manuals like the Bentley manuals have been the go-to source of information for fixing VWs. However, since 2009, VW has decided to switch to an online platform for repair information. This platform is called erWin and can be found at erwin.vw.com. In this article we’ll review what it is and how to use it… erWin is an online portal that provides comprehensive and up-to-date repair and maintenance information for all Volkswagen models. The system includes wiring diagrams, service schedules, technical servi ..read more

The Mercedes BlueTec Settlement gave cars and extended warranty on most of the emissions and fueling system, including the diesel exhaust fluid (DEF) or additive system… What does the DEF Additive Supply Line Do? The DEF Additive Supply Line connects the additive pump (aka sending unit) – which is typically located in the DEF tank to – to the DEF injector which is attached to the exhaust system before the NOx catalyst. What is covered under the Mercedes BlueTEC Extended Emissions Warranty? This varies slightly by vehicle, but largely the following components are covered: Diesel Oxidation Cata ..read more