PD INJECTOR REMOVAL and Install
OK THIS IS TAKE 2 . ill do it in spurts to make sure i dont waist an hour and a half again. this post will take me a couple of days to finish as i have to collect all my pics. and i dont have the book so i will not have trq's so if you do feel free to chime in.
OK here we go . first you need to remove the up pipe from the IC and the shutter valve on the intake manifold. i sugest a towle to place everything on so you dont loose them and now is also the time to clean them . next thing you need to do is remove the TB cover i dont have a pic of this so sorry . as i remember its just clips . then you need to remove the EGR plunger . It has 3 hexegonal bolts holding it into the intake manifold.
first you want to unplug it. then remove the 3 bolts 1 on top 1 on botom and one that is under the plug you can barely see in this pic.
Next you discon the hose from the valve cover breather to the down pipe. Then you need to loosen the captive bolts that hold the valve cover down. they are captive so do not pull them out. Three of these also hold your fuel rail inplace. once you remove the valve cover it will look like this.
you can see the hole where the egr plunger goes
Also cover the TB to keep from nicking it or getting oil on it.
as you can see i put towels in the block under the injectors . thats to keep everything out of the engine. there are oil drain holes there.
Now you need some tools to remove the injectors a 12 point triple square wrench set. plus a small crowbar.
now you need to remove the 1st 4 bolts from one of the rockers that are bolted to the head and rest on the cam. i started on the left and worked right. once you remove these 4 bolts you can remove it or do as i did and just rotate it back and sit it on the cam . there is no need to mess with the lock nut over the injector it is not connected to it. at this time measure the gap between the injector and the block on the right of the injector. i used a feeler guage. (again if you have a book here is were to put your 2 cents) i just put them all at the same gap and its fine. if you dont your car will sound like its caming. but only at idle. by gap i mean if you turn it more left or right the gap will change.
Here is the vid for this part. http://media.putfile.com/VW-PD---TDI-Injector-Removal
Now you need to discon. the plugs from the injectors . be very carfull not to break them . i used a set of pliers and went really slowly. their really in there.
Next you need to remove the bolt that holds in the wedge on the left side of the injectors. once you get it out slide out the wedge . you might have to pry the injector back and forth a little to get the wedge out.
Once you got the wedge out your ready to pull out the injector. its better if you do this while the engine is warm .(not hot) but warm. B/C the injector is held in by orings . so now just move it back and forth with the crowbar this will loosen it. then really slowly pry it out. once you got it out cover the hole to make sure nothin gets down into it.
due this for every injector.
here it is with the injector removed . you can also see the rocker rolled back off or the injector and cam.
This is the injector as you will get it from kerma. see the cap on the tip make sure and pull it off . i got in a hurry . the wife was blowing up my phone. well a long story short i put the 2nd one in with out taking it off and i broke the wedge bolt off in the head and its a real pain b/c its right by the head wall on the left. And the concave piece on the top the one you can see sticking outat the bottom of this pic and will see in other pics i post will come out so be carefull.
INSTALL
i dont have much for this just put it back the way it came apart.
You need to lube the orings on the injector i used veg oil. then once you got it together pull the glowplugs out be carefull not to drop them as i have heard they are easy to damage. turn the engine over a couple or times this will shoot out any extra fuel that is in the engine . once you do this put the glow plug back in and start her up. and enjoy.
there are more pics ont the way and any thing else any one knows from the book ill also put in here
the vids are not much but they're somthin at least.
When i do the swap next time when i get the UFO's ill vid the whole thing and put it on dvd or cd so i can give it out.
OK THIS IS TAKE 2 . ill do it in spurts to make sure i dont waist an hour and a half again. this post will take me a couple of days to finish as i have to collect all my pics. and i dont have the book so i will not have trq's so if you do feel free to chime in.
OK here we go . first you need to remove the up pipe from the IC and the shutter valve on the intake manifold. i sugest a towle to place everything on so you dont loose them and now is also the time to clean them . next thing you need to do is remove the TB cover i dont have a pic of this so sorry . as i remember its just clips . then you need to remove the EGR plunger . It has 3 hexegonal bolts holding it into the intake manifold.
first you want to unplug it. then remove the 3 bolts 1 on top 1 on botom and one that is under the plug you can barely see in this pic.
Next you discon the hose from the valve cover breather to the down pipe. Then you need to loosen the captive bolts that hold the valve cover down. they are captive so do not pull them out. Three of these also hold your fuel rail inplace. once you remove the valve cover it will look like this.
you can see the hole where the egr plunger goes
Also cover the TB to keep from nicking it or getting oil on it.
as you can see i put towels in the block under the injectors . thats to keep everything out of the engine. there are oil drain holes there.
Now you need some tools to remove the injectors a 12 point triple square wrench set. plus a small crowbar.
now you need to remove the 1st 4 bolts from one of the rockers that are bolted to the head and rest on the cam. i started on the left and worked right. once you remove these 4 bolts you can remove it or do as i did and just rotate it back and sit it on the cam . there is no need to mess with the lock nut over the injector it is not connected to it. at this time measure the gap between the injector and the block on the right of the injector. i used a feeler guage. (again if you have a book here is were to put your 2 cents) i just put them all at the same gap and its fine. if you dont your car will sound like its caming. but only at idle. by gap i mean if you turn it more left or right the gap will change.
Here is the vid for this part. http://media.putfile.com/VW-PD---TDI-Injector-Removal
Now you need to discon. the plugs from the injectors . be very carfull not to break them . i used a set of pliers and went really slowly. their really in there.
Next you need to remove the bolt that holds in the wedge on the left side of the injectors. once you get it out slide out the wedge . you might have to pry the injector back and forth a little to get the wedge out.
Once you got the wedge out your ready to pull out the injector. its better if you do this while the engine is warm .(not hot) but warm. B/C the injector is held in by orings . so now just move it back and forth with the crowbar this will loosen it. then really slowly pry it out. once you got it out cover the hole to make sure nothin gets down into it.
due this for every injector.
here it is with the injector removed . you can also see the rocker rolled back off or the injector and cam.
This is the injector as you will get it from kerma. see the cap on the tip make sure and pull it off . i got in a hurry . the wife was blowing up my phone. well a long story short i put the 2nd one in with out taking it off and i broke the wedge bolt off in the head and its a real pain b/c its right by the head wall on the left. And the concave piece on the top the one you can see sticking outat the bottom of this pic and will see in other pics i post will come out so be carefull.
INSTALL
i dont have much for this just put it back the way it came apart.
You need to lube the orings on the injector i used veg oil. then once you got it together pull the glowplugs out be carefull not to drop them as i have heard they are easy to damage. turn the engine over a couple or times this will shoot out any extra fuel that is in the engine . once you do this put the glow plug back in and start her up. and enjoy.
there are more pics ont the way and any thing else any one knows from the book ill also put in here
the vids are not much but they're somthin at least.
When i do the swap next time when i get the UFO's ill vid the whole thing and put it on dvd or cd so i can give it out.
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