Fuel Injector Removal: V6 2.5 TDI Engine

Hey guys, does anyone happen to know how to remove the fuel injectors on a V6 2.5 TDI engine?
I tried to remove a nozzle the other day, but unfortunately, I wasn't successful.

I basically unscrewed the top part of the bracket, and then the nozzle should have come out, right?! But somehow, it didn't work. Do you need any special tools for that? Or is there a trick to it?

Regards,
Al.

Okay, so if it's an engine with a VEP, you have to turn the nozzle a few degrees back and forth with a wrench of the appropriate size, while simultaneously pulling it upwards. For the 4-cylinder engine (which is the same principle), there are some good guides available, e.g., https://community.dieselschrauber.org/en/viewtopic.php?t=10197.

Best regards!

You screw a drift onto the threaded portion of the nozzle holder. This should then allow you to remove the nozzle holder.

I'm always careful when using the sliding hammer. You can definitely use a wrench for that. By the way, this also works for the 1Z and AFN engines!

Was soll den mit dem Gleithammer schief gehen. I once...
I built something like that years ago, and it works really well!

Well, there are just a few adjustments you can make to the engine. I'm always a little cautious about that...
I just find the whole "turning humans" thing disturbing...

cksIT wrote:

Well, I guess there are just a few punches,

Okay, then think about what kind of impacts are coming from the inside!

Turning also works. It's always been a good method to persistently rotate with moderate force in both directions, even if you don't see results immediately. Eventually, it will wear things down. Not just ESD, but also tie rods and other components. The problem with nozzle rods is that they might break down themselves during the process. So, even less torque and many more cycles.

Thanks for the tips. I managed to get the nozzle out. I carefully gripped it with pliers, wiggled it back and forth a couple of times, and it came right out.

Regards,
Al.

@altonno,

Do you notice any difference with the new nozzles? How much did yours decrease?

Best regards,
Rainer

My injectors had approximately 180,000 kilometers (or miles) on them. I haven't noticed any improvement with the new injectors, even though the old ones had a faulty needle lifter.

Regards,
AL