Fuel Injector Problem: Diagnosis & Repair

Hello.

I have a problem:

Golf 3 TDI 110 hp, engine code AFN.

'I've had the fuel injector line number 3 break several times! I've replaced it multiple times, but it always breaks again! This happens within 200 km on the highway, at a speed of 160 km/h.'

I used these plastic clips to securely fasten the wires, so they wouldn't vibrate and break.

But: nozzle number 3 is vibrating in the cylinder head! I've already tried replacing the copper ring, but there's no improvement; the nozzle continues to vibrate!

Who can help me?

Hello, perhaps the claw is bent, so that it doesn't apply enough pressure to the nozzle.
Nozzle 3 should be the needle lift adjuster (there's a cable connected to the nozzle).
I think I'll replace the claw.

Hello,

Is the fuel injection pump properly tightened?

Best regards, Rainer.

Hello,

You've almost given the answer yourself. Nozzle number 3 is wobbling in the print head.
Either the nozzle is completely defective in terms of its fit, or there's something wrong with its installation on the cylinder head. Besides the copper ring, have you also checked the clamping bracket and the clamping nut? Furthermore, the fuel injection line must not be installed under any mechanical stress. The clamping nut must be tightened to 20 Nm, and the fuel injection line itself must be tightened to 25 Nm.

Hello, maybe the claw is bent, so that it doesn't apply enough pressure to the nozzle.
Nozzle 3 should be the needle lift adjuster (there's a cable connected to the nozzle).
I would like to replace the claw.

Thank you in advance, I'll try it out on Saturday!

Hello,

You've almost given the answer yourself. Nozzle number 3 is wobbling in the print head.
Either the nozzle is completely defective in terms of its fit, or something is wrong with the mounting on the cylinder head. Besides the copper ring, have you also checked the clamping bracket and the clamping nut? Furthermore, the injection line must not be installed under mechanical stress. The clamping nut must be tightened to 20 Nm, and the injection line itself is tightened to 25 Nm .

I am absolutely certain that the fuel injection line is not under any mechanical stress.

I'm going to try using a new keyboard and mouse, let's see what's available.

I will send you more updates tomorrow if there is any news.

Broken again last week!


Tomorrow I'm going to try:

- new claw
- new copper rings
- new single-track line (the fourth... grrr)
- new bolt, etc.


Let's see what happens and whether the nozzle remains flawless and vibration-free.