TDI Fuel Injector: Help Needed in Bad Sobernheim

Hello everyone,

zuletzt hatte ich ja Probleme mit meiner Einspritzpumpe. Das Zerlegen derselben zeigte einen völlig zerstörten Verteilerkolben, die Bilder hierzu bin ich euch noch schuldig. Nun habe ich eine gebrauchte Ersatzpumpe eingebaut, bzw. vorher gleich mal neu abgedichtet, wenn ich sie schon in der Hand habe. Nun ist die Pumpe angebaut, voll Diesel, und wenn man den Anlasser betätigt kommt aus allen vier Leitungen des Einspritzgeweihs auch mit ordentlich Druck Diesel gespritzt. So far, so good.

Okay, now we're back to Spanish. The engine isn't firing, and there's no smoke or smell coming from the exhaust, meaning there's no partially or completely unburned diesel. This indicates that the diesel isn't being injected at all, not even at the wrong time. Furthermore, nothing is coming out of the leak-off line. In fact, nothing is coming out of the disconnected leak-off line at any of the injector ports; suspiciously, there's even vegetable oil present there, which probably caused the last pump to fail. Notably, the reconnected fuel injection line is still spraying diesel, so where is the diesel going? I assume the injectors are clogged or carbonized, but then it should be flowing back through the leak-off line, right?

Okay, I have a set of injectors here because I was planning to replace them anyway at 215,000 km, and I also have an injector testing device. However, those darn injector sleeves wouldn't budge today. As described in the forum, rocking and pulling doesn't seem to help at all (!). Does anyone have an injector removal tool? It seems like there are only makeshift solutions available. Could anyone lend me one? My experience has been that using the right tool saves more time overall, even if it requires a longer trip.


However, I'm also gradually losing the motivation, so perhaps someone lives near Bad Sobernheim and would be willing to help me tomorrow (Sunday, November 5th) or in the coming days? Of course, this wouldn't be for free.


What probably still needs to be done is to clean the nozzle bodies and replace the nozzles, which should be quite quick with the right tool to remove them. Presumably, the nozzles are clogged or something.
Adjust the fuel injection pump; I have VAG-COM and some knowledge, and then possibly correct the valve timing. Well, if the engine starts running again, I'll be fine, but right now I'm very frustrated.



The best way to reach me is by phone: 0176/21172587.


Alternatively, I would also appreciate any tips or encouragement you can offer.

Best regards,

Udo.


The engine is a 1997 AFN TDI with 110 horsepower, installed in a VW Passat. The ESP, model VP 37, Bosch part number 0 460 404 969, is electronically controlled.

Hi.

"Where exactly does the diesel fuel come out when you unscrew the lines?"

Located directly on the high-pressure side are the equal-pressure valves. If you thought they were simple connection plugs and removed them *with* the lines, they might be blocked, which could cause the damage you described.

Otherwise, disconnect a line from the main system and attach a nozzle, put on safety glasses and gloves, and then try running it (attempt to start).

Somewhere, the saliva has to go, or the pump is providing far too little pressure (meaning it's broken) to move the nozzles and open them.

m;

Hi Martin,

Thank you for your answer .

"So, I left the four valves on the back of the pump in place, and the fuel is reaching the end of the injector lines, so it's spraying out of those lines, which are connected to the nozzles. Unfortunately, I can't test if the pressure is high enough right now; I would need to be able to remove at least ONE of the injector bodies. I only have the nozzles themselves; I don't have the complete injector bodies. However, if I can get one of those bodies out, I'll test the pressure first. Why isn't the diesel draining through the leak-off line?"

So, until the fuel pump failed, the car was working perfectly. It was parked 'properly', and I tried to start it again in the evening, but nothing worked. If nothing else helps, I'll take the pump to a Bosch service center next week; they should have a fuel pump testing stand. If only I could get the injector nozzles out...

Greetings.

Udo.

If the nozzles don't open, nothing will flow into the return line.

That's how I interpret the cross-sections from BOSCH, at least.

m;