Replace V6 Injectors: Guide & Parts

Error:
My Passat V6 4Motion (BDH) had poor engine performance and excessive fuel consumption. I decided to investigate, and after reading the diagnostic data (mass comparison), I noticed significant fluctuations. (Interestingly, only 5 cylinders were displayed; one was missing). The fluctuations were also higher at warmer temperatures than at cooler temperatures.
After removing the injectors, I pressure tested them and found that they only start to open at approximately 30-40 bar, and the needle movement doesn't even occur until about 70 bar above that (normally around 180 bar).

Now I want to change the nozzles...
Now, my question is:

If I have them repaired (e.g., by Bosch), they will replace the injector nozzles, adjust everything, and also verschandeln them.
If I buy a tuning kit and assemble it myself (and adjust it).
"However, I can't rinse or verschandeln them. Is it even worth doing that, or can I just skip that step and replace the heads instead?"

"How much would it cost to get some new heads (tuning)? I haven't found any options here yet."
Do I need to adjust the engine map here in order to achieve a performance increase?
Are they as durable as the original ones?

Perhaps someone can help me and advise whether this conversion is actually worthwhile.

Best regards,

acuransx wrote:

If I have them refurbished (like at Bosch, for example), they will replace the injector nozzles, adjust everything, and also verschandeln them.

If you order it like that, yes.

acuransx wrote:

If I buy a tuning kit and assemble it myself (adjust it), but I can't flush/verschandeln it, is it even worth doing, or can I just skip that step and put in new heads...?

When you buy new injector nozzles, they are usually clean. If you pay attention to cleanliness when disassembling, you won't need to do any cleaning yourself.

acuransx wrote:

And do I need to adjust the engine map here to achieve a performance increase?

Yes, to fully utilize it.

acuransx wrote:

Are they as durable as the original ones?

Yes, if you're not buying some cheap, mass-produced garbage from China.

With the V6 TDI engine, everything is different. You can't normally adjust them, but Rainer used to have a trick for it, although he doesn't offer that anymore. 180 bar is incorrect; 230 bar is the correct value.
Only 5 nozzles are displayed because these values are relative to the second nozzle, which would always have a value of 0.00 mg/cycle.

"The ESI specification states 180-190/160 bar, so how do you arrive at 230 bar?"
"Because otherwise they were fine, except for the pine needles."

How come the values there are not correct?

Only 5 nozzles are displayed because these values are relative to the second nozzle. Therefore, the reading for that nozzle would always be 0.00 mg/cycle?
I don't really understand.

acuransx wrote:

So, the ESI specification states 180-190/160 bar. How do you arrive at 230 bar? They were fine otherwise, except for the pine needles. Only how come the values there don't match?

It's possible that Christians was looking for an automatic transmission, but you have a manual one. With an automatic transmission, the pressure is usually set higher to ensure the engine continues to meet its emissions standards.

acuransx wrote:

Only 5 nozzles are displayed because these values are relative to the 2nd nozzle, which would therefore always be 0.00 mg/hub???????????? I DON'T REALLY UNDERSTAND

.

It's a comparison of quantities. To make a comparison, you need something to compare against, a reference point. In this case, the second nozzle is used as the reference point, and all the other nozzles are compared to it.

If you still don't understand it now, I don't know what else to say.

I understand this much so far..., but I don't understand the purpose of the measurement.

If all the nozzles are broken (including the second one), and if it's assumed that the second nozzle is reading zero, then the other values are also likely incorrect.
Well, I still think it's sausage because of the quantity adjustment. If they only open at 240 degrees, that's not right... Also, they've been taken out [of something].

Yes, I have a gauge, so the value is already correct at 180-190 bar.

Now I just need to quickly find a way to get some new nozzles from somewhere.

Quote:

Yes, I have a switch, so the value is already correct at 180-190 bar.

No.

Perhaps you checked the part compatibility for the V6 TDI engine using a different engine code (MKB) due to the pressure issue?

The purpose of the measurement is to identify faults in individual nozzles. Of course, there are also fault patterns where everything appears to be okay, but a fault still exists. However, such rare errors occur everywhere.

"So, what's the correct pressure for this then?"

"No, you were already the right one... it's all the same everywhere, which is why these statements here are making me a bit suspicious."

Regarding the quantity comparison... when comparing quantities, they should be approximately equal. However, in this case, the values ranged from -2.8 to +2.8, and each was different. The target value is +/- 1.5.

Well, the prices are also very different, but what is the right one?

Sure, here is the translation of the text from German to English:

"MFG" stands for "Mit freundlichen Grüßen," which translates to "Sincerely" or "Best regards" in English. It is a common way to end a formal letter or email.

See, the measurement was worthwhile after all. I don't know the correct pressure either; I don't have that level of detail from the V6.

Well, I just checked on the ESI website...
Interestingly, no matter where you look or what engine code it is, the pressure reading seems to be the same everywhere. I just noticed that.

Maybe someone still knows the correct pressure.

You could also check directly on the nozzle itself to see if it's printed there. It's marked on the 1.9 TDI, but I don't know if it's the same for the V6.

Unfortunately, there's nothing written on it.
Let's see...

220, 230, or 231 bar – as mentioned above!

And 160 bar as a "wear limit" or whatever that value stated above represents is already an extremely high number -> making it unusable.

Okay, Bosch states that as described above. Isn't ESI-Tronic a Bosch product?
It says 180-190/160 bar, no joke. I just checked again, and it's listed for almost every engine code.

Okay, then I'll set it to 220-230.

If you use larger nozzles, do you need to adjust the pressure accordingly, or can you maintain the same pressure?

Sure, here is the translation of the text from German to English:

"MFG" stands for "Mit freundlichen Grüßen," which translates to "Sincerely" or "Best regards" in English. It is a common way to end a formal letter or email.

acuransx wrote:

If you use larger nozzles, do you need to adjust the pressure, or is it the same?

If you don't go overboard with the size, you can probably have them installed as a set. I also think there might not be sizes that are too big for the V6 engine.