Injector Replacement: 2.5 TDI Engine

hello,

I'm looking for some quick advice. The five injectors for my Audi 2.5 TDI engine in the Volvo are very expensive (almost €1000). I'm now considering the alternative of just replacing the injector nozzles. I've also received an offer for nozzles for all the injectors, including those for NHG (which, according to what I've read, isn't possible?).

Is this a good alternative, or should the entire nozzle (including the pins and nibs) also be replaced?

Problems with the 1/4 million km injectors: rough running, misfires, maximum speed of 190 km/h, excessive fuel consumption.

Thank you for your information!

greetings
uwe

No, that doesn't make sense.
There are also complete, pre-assembled and calibrated nozzle holders available for around 500 EUR. However, it's not always easy to find a supplier who sells them.

Hello. Thank you for the answer. Sorry if I'm misunderstanding something, but the nozzles must fundamentally work. Then I can install them, whether they are new or repaired, that's a secondary issue...

What do you think about being hired?

The only thing I'll adjust is the ESP, to make sure it's perfectly calibrated again.

Assuming that replacing the injectors doesn't solve the problem, what is the defective part within the injectors?

Thank you for your help!

Hello,

I would like to inquire at dieselsend.de.
There's already the NBF nozzle holder combination available for (if I remember correctly) 130 euros, and the other nozzles without the NBF feature are likely cheaper.

Otherwise: Why are you so sure that the injectors are bad? I have a family member with an 850 TDI with 300,000 km on it, and it doesn't smoke noticeably.
You might have a leak in the charge air duct, or a clogged EGR valve.


Greetings, Georg.

hello,

agr is extremely clean, and it has been for quite some time. I'm sure it's the nozzles; I had them checked months ago.

I just need to know if it will make a difference to replace the components. If that's the solution, then I'll do it that way, as it's much cheaper.

I personally believe this helps when my nozzles are clogged. Surely, the springs and nibs can't contain anything, right?

Thank you for your help.

Enjoy your meal!

Of course, you could also just swap the components, but do you have the expertise and the...
necessary equipment, adjustment tools...?

For the vertebral body cages in the anterior column system, you need, for example, a punch tool and...
"Shim washers and you should have done this before, the TDI injectors are definitely something..."
demanding.

Hi, Jockel.

Hmmm.

Okay, so I completely disassembled the injectors.

Then I cleaned them.

and then reassembled.

That was six months ago - it was a little better since then, but there was nothing I could adjust.

I can disassemble it and replace the parts, but what adjustments should be made afterwards?

Sorry for my confusion.

Simply disassembling the part and installing new components won't work. Go to a local engine rebuilder and discuss the issue with them. They work on many engines every day and replace injectors frequently, so they have all the necessary spare parts and the expertise for a proper repair. Also, their prices are usually reasonable. Best regards, Jürgen.

Okay, since I'm here in the middle of Austria... there's a local one for sale for €1500. That's too much.

But if you're telling me that I can't just replace the injectors myself, then there's no way around it. I'll have to take it to a Bosch service center.

I was just thinking like, you know, crayons – old ones out, new ones in, and then you're ready to go.

Hi,


"As far as I know, on the TDI injector pump housings of this generation, the only thing that can be adjusted is the opening pressure. And Bosch service can do that for you (at least a Bosch Diesel Center, but you've already been there, as I understand it)."

In that case, you could simply buy 5 new injector bodies for around 90 euros, install them, and have Bosch check the entire injector to ensure the opening pressure and spray pattern are correct. If everything is okay, then it would be fine.

On the other hand, I would buy completely new nozzles for the mileage. If you're going to do it, do it right. The springs contained within the nozzles are also subject to a certain amount of wear and tear.

Personal tip: Doing things thoroughly saves you a lot of trouble in the long run.

Best regards, Georg.

Thank you, Georg.

You are right.

"Does that mean that if I buy new injectors (or, in the case of diesel injectors, they are actually rebuilt and not truly new), I can install them myself without any adjustments, and the engine will run? Or do they need to be adjusted as well?"

Hi,

Speculation:
I don't think the nozzles have been repaired. They are most likely brand new. That's certainly different from the nozzle holder, which is the part with the spring and the fuel line connection.


If I were only to replace the injectors, which I plan to do soon, I would disassemble them myself, replace the injector, and then cycle the bike to the Bosch service center to have them pressure tested. If the pressure test is successful, I will install the injector holder assembly (making sure to align it perfectly in the center!).

Use new, original Audi/VW copper sealing washers!

I wouldn't install them without properly testing them first. A TDI engine is just too expensive a toy to risk it.

Best regards, Georg.

Okay, so I think it's best to have Bosch install it directly.

Thank you very much for the help. Just one quick question on the side.

What exactly are they doing when they "print"? I think I misunderstood something.

"The quick brown fox jumps over the lazy dog."

Hello,

The spray pattern (visually) and the opening pressure (measured with a pressure gauge) are checked. This is done using a device into which the nozzle to be tested is installed, and then the diesel pressure is built up using a lever.

Best regards, Robert.

"Thank you!"

If the nozzle is new, it should already be properly adjusted, right?

Okay, so I can repair my injectors, then have them cleaned, and then install them?

Greetings and thank you.
uwe

Okay, one more question: What can be changed during the "printing" process? I mean, nothing can be adjusted on the nozzle itself, right? Or is there a way?