Fuel Injector Lines: Broken & Repair

Hello.

I'm having another problem again!

'Currently, I'm experiencing a problem where the fuel injection lines are breaking one after another. First, it was the line for cylinder 3, then last Thursday it was the line for cylinder 1, and today it's again the line for cylinder 3. What could be causing this? Are the lines installed too tightly? Is there anything specific to pay attention to when installing them? Some time ago, the fuel injection timing was adjusted, and after that, the lines were loosened to relieve tension.'

Best regards,

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

'Didl' is a German word that means 'a small amount of something.' It can be used to describe anything from a tiny speck of dust to a large pile of sand.

Here are some examples of how to use 'Didl' in a sentence:

* There was only a didl of sugar left in the jar.
* The children were playing with a didl of sand on the beach.
* He had a didl of money saved up for his trip.

I hope this helps!

didl wrote:

Some time ago, the injection timing was adjusted, and then the lines were loosened to relieve tension.

Hi.

In my opinion, it's actually hard to do anything wrong here - except maybe forgetting the two small "bridges" that each support and stabilize two wires.

ulf wrote:

In my opinion, it's actually quite difficult to do anything wrong here - except perhaps forgetting the two small "bridges" that each support and stabilize two lines

.

Hi everyone,

I once bent a hose at my old car because it wasn't in the right place (I was too lazy to take the others apart...). The hoses were then partially touching each other for 140,000 kilometers because the spacer wouldn't fit. There were never any problems... of course, the pressure surges in a TD are also lower than in a TDI .

@Didl:

During installation, as Ulf already mentioned, you can't really do anything wrong, unless the nuts are tightened too much (narrowing, twisting -> micro-cracks?). When tightening, a considerable amount of force is applied to the lines. If you use excessive force, it can cause permanent stress! Where exactly are these things breaking for you? I only tighten the lines slightly, and if one leaks, I just tighten it a little more. }

Hi,
I'm having the same problem because the screw on the ESP (at the back) broke, and the pump started vibrating. It always failed on the third cylinder.

Thank you for the quick responses!

The first cable was torn in an arc shape, while the other two were torn straight.

Are the spacers that important? When the first 'break' happened, the spacers were still in place, but I was careless when taking it apart and broke them off. I didn't put them back in. I didn't think much of it; I just made sure that the wires weren't touching each other!

Best regards,

Stefan.

didl wrote:

Are the shims that important? When the first "break" occurred, the shims were still in place, but I was careless when taking it apart and broke them, and didn't put them back in.

Hi Stefan,

While the VP 37-EDC has been somewhat overshadowed by PD, it is still a highly refined product.

Pump experts may correct me, but as far as I know, the connecting pieces have more important functions than just preventing pipes from bumping into each other – namely, they also contribute to micro-vibration damping, which in turn helps prevent fractures.

ulf wrote:

The pump experts may correct me, but AFAIK, the intermediate pieces have more significant functions than just preventing the pipes from bumping into each other - namely, they also contribute to micro-vibration damping, which in turn is related to preventing fractures.

Hello Ulf,

Everything is correct. Therefore, the core package should not be split up either.

In my opinion, the cables should always be replaced as a complete set and must never be twisted or installed under tension.

More details can be found in the repair manual.

Stefan.

Stefan . wrote:

In my humble opinion, the cables must always be replaced as a complete set and should never be twisted or installed under tension.

Hi everyone,

Okay, so I have removed individual lines from three different TDI engines (mostly the ones from the NBF), and in one case, the "spacer" even broke into two pieces, and I only reinstalled one part... In the TD engine, as described above, I sometimes bent the lines and installed them without the spacer -> so far, not a single problem .

The quick appearance of the issue after adjustments to the pump sounds very much like an overtightened union nut, or loose pump fittings . It's also conceivable that there was cross-threading when loosening it (I experienced this with my TD back then... but it lasted almost 300,000 km! -> TDI?).

I certainly don't intend to question the theory, but rather to share my practical experiences .

The rear screw of the fuel injection pump is missing; let's see if that was the cause.

I am still grateful for any tips you can offer!

Do you think those plastic brackets between the cables are that important? Should I buy new ones?

Best regards,

Stefan.

didl wrote:

The rear screw of the fuel injection pump is missing; let's see if that was the cause.

Hi Stefan,

aaaaaah, Tim was right with his assumption....when the screw is missing, there are significant vibrations ...I need to check mine now...the cone rotated when I tightened it last time .

If the brackets are in good condition, you can just leave them as they are .

Hello,
If you're looking at the rear screw on the pump, also check the pump bracket where the pump is attached to the engine block!

After approximately 3 broken fuel injection lines, I had to realize that my pump bracket was broken due to the vibrations. The pump was only held in place by the fuel injection lines, and the timing belt was only partially attached. :lol:

@haenlein

Which brackets are you referring to? The spacers between the wires? Those were all broken when I opened it up... so I need to put in new ones, right?

Best regards,

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

'Didl' is a German word that means 'a small amount of something.' It can be used to describe anything from a tiny speck of dust to a large pile of sand.

Here are some examples of how to use 'Didl' in a sentence:

* There was only a didl of sugar left in the jar.
* The children were playing with a didl of sand on the beach.
* He had a didl of money saved up for his trip.

I hope this helps!

didl wrote:

The spacers between the wires? I broke all of them when I opened it up... so I need to put in new ones, right?

That's exactly what I mean. Well, those three parts are probably only available as genuine parts from the dealer ... it certainly can't hurt to ask .

Hi,
I mean where the pump connects to the engine block, or rather...
'The bracket where I attach the pump with three screws is broken right behind the pump.'

tim27 wrote:

I mean where the pump connects to the engine block, or rather... because the bracket where I attach the pump with three screws is broken right behind the pump in my case.

Hi Tim,

You didn't use the torque wrench and tighten it to 25 Nm, or ... I can't explain how the studs would otherwise break .