Injector configuration

Joined
Dec 4, 2023
Location
West Sussex
TDI
1.9 TDi match
We’ve had our TDi match for 20 years and it’s been brilliant, always serviced and well looked after. Last year the nightmare began.. engine management light came on and car went into limp mode. Diagnostics revealed faulty injector. Garage (we were away so not local to us) replaced 1 & 3 injectors and the car was fine for a few months. Car then intermittently mis fired slightly until one day it wouldn’t drive. Local garage diagnosed one of the replaced injectors faulty and one of the older injectors faulty so replaced both. Car was 90% there; gentle acceleration absolutely fine but if you put your foot down hard the car felt as if it was mis firing. We kind of accepted the limitations as the car is primarily used for local runs and the bills were mounting on a car probably worth £1500 but more to us having owned and looked after it for so long. Last night the engine management light came on and the car went into limp mode.
Car goes back for diagnostic on Thursday.
Is there a PD injector guru out there as the local garage (who I’ve used for 13 years and trust) admit that they are struggling to get the configuration right or spot on ?
 

PakProtector

Veteran Member
Joined
Jan 5, 2014
Location
AnnArbor, MI
TDI
Mk.4's and the Cummins
Have to suggest Darkside. They are comparatively local...and for my level of paranoia, I do dislike the idea of replacing just one injector. I would rather put in a set of properly rebuilt ones. But that sentiment does you no more good than it does me... :) PD injectors are just going to be more expensive.

Douglas
 
Joined
Dec 4, 2023
Location
West Sussex
TDI
1.9 TDi match
Thanks Douglas but we’re in West Sussex on the south coast and if I’m not mistaken Darkside are in Barnsley ?
The car has cost us nothing in 18 years of motoring but last 18 months £650 clutch, £600 2 x new injectors/labour and £1600 2 new injectors and labour. Very frustrating as I am sure if I could find an experienced PD injector mechanic everything should be fine. Can’t afford to throw money on a 20 year old car #frustrated.
 
Joined
Dec 4, 2023
Location
West Sussex
TDI
1.9 TDi match
Hi and yes according to the garage who initially suspected cam wear and whilst I trust them I’m not sure whether they have enough experience on PD injectors.
 

PakProtector

Veteran Member
Joined
Jan 5, 2014
Location
AnnArbor, MI
TDI
Mk.4's and the Cummins
I can think of few folk I would trust to examine a PD cam. It is a bit time consuming to do properly( roll engine, look, roll engine, look... ). I got to where mine was showing wear. I had a younger engine that I did examine carefully and instead of replacing the cam on the original, just pulled the whole mess. Did a timing belt, clutch and rear main while in there...

And you nail the PD injector conundrum properly, they last until the bill for replacing them is a significant part of the car's value. Even over here in the States where a set of re-nozzled, performance-checked pumps is about $1250 in parts.

However, since I enjoy driving these olde beasties, and REALLY like them turned up a bit, I am going to manage a replacement... :)

Douglas
 
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