[Vwdiesel] 92 ECO injectors

Tue Aug 10 14:08:48 EDT 2004

I disconnect the bar, and just leave it near the plugs.  Usually the 
#3 remains connected for the testing.

Many in the group have replaced the bus strip with 4 individual wires.
If I had a car with dripping injectors, or with the runaway problem,
where glowplugs tend to get eaten often, then I would have switched to 
a 4 wire system.  I haven't had to.

Actually, my 1977 Rabbit went for 270kmiles without the glow plug for
#1.  When the car has less than 30k on it, the #1 failed.  When I went 
to remove it, the 12mm head broke off.  The car started just fine for 
many years.  

I could never lever (with tire irons) an EZ out into that glow plug 
for extraction.  I even specially ground one.  Later when the head came 
off, I found I could walk the old glow plug stub out just fine.  Go 
figure.  Back in those days, I didn't have a garage to work in.  Life is
good now.

Oh for the buss bar, a 8mm long pattern Sears wrench is OK.  I also
use an 8mm socket on 1/4" drive tools.  A magnet tool to pick up
dropped nuts is great, and a needle nose to remove and replace the wavy 
washer helps.  For placing the nuts, I'd wrap a little masking tape on
my finger, put the nut on it, and place the nut on the end of the 
glow plug terminal threads.  Then with the open end of the long pattern 
8mm wrench, I'd start the nut onto the threads.  You only need to tape 
trick for one or two of the cylinders.

Have fun!

Val

> 
> Val - do you disconnect the current bar across all glow plugs before
> testing with battery charger?  If not, how do you go about testing one
> from another?
> 
> Chris
> 
> 
> -----Original Message-----
> From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com]
> On Behalf Of Val Christian
> Sent: Tuesday, August 10, 2004 8:34 AM
> To: TexasTDI; vwdiesel at vwfans.com
> Subject: Re: [Vwdiesel] 92 ECO injectors
> 
> Based upon experience, I would go after glow plugs.  You'll probably
> find 
> you have two bad.  I check them with a battery charger, and look for 
> current flow.  An ohm meter is not reliable, because they fail by
> element 
> erosion, which, like in an incandescent light bulb, causes a hot spot,
> but 
> overall cooler operation.  (Hence the yellowish color of an old
> incandescent
> lamp.  It's yellow, because it's cooler.)
> 
> Your injectors may also be a problem, and there are many who have played
> with injectors here and will offer better advice than I.  My experience
> with
> them is that they fail less often than glow plugs.  Generally timing
> changes,
> dribble causing glow plugs to look as if they've been cut with a torch, 
> lower power, smoking at temp, etc. are symptoms.
> 
> The white smoke you see is uncombusted fuel, which is from the
> cylinder(s)
> which aren't firing up at the initial start.  Eventually, those
> cylinders
> heat up from friction, and conductance from adjacent cylinders, and
> perhaps
> partial combustion.  The noise is different, because you're not burning
> things
> as usual.  Others can talk about that better than I, because they've
> played
> with timing and injector settings, and know the different noises.
> 
> Is this a TDI or an IDI, as there will be some symptomatic differences 
> between each.
> 
> Time to get the battery charger out, and a long screwdriver (the probe)
> and
> check those plugs!
> 
> Val
> 
> > 
> > How can you tell the difference between failing injectors and failing
> glow
> > plugs?  I think I have one or the other, or maybe even both.  Not too
> > mention MAF problems as well.
> > 
> > I'm currently running with the MAF unplugged until the new one comes
> in.
> > But now in the morning, when the engine has been sitting for at least
> 8
> > hours overnight and is cold, it starts but does so sluggishly.  Idling
> very
> > rough until I step on the accelerator.  Then a nice cloud of white
> smoke
> > appears.  After a few minutes, when the car has warmed up, it idles
> fine.
> > 
> > This past winter (2003) I would sometimes have to cycle the GP's two
> or
> > three times for the car to start.  Didn't have to do that during the
> prior
> > winter (2002).  Also, I'm noticing a very distinct noise near the fuel
> pump.
> > A loud clatter over and above the normal diesel clatter.  It's hard to
> > pinpoint the exact location.  But it's definitely coming from the top
> of the
> > engine, on the passenger side, near the fuel pump and timing belt.
> > 
> > Failing GP's ?
> > 
> > Failing injector(s) ?
> > 
> > Failing fuel pump ?
> > 
> > Christopher J. Thornton
> > 1991 VW Jetta 2 Door 1.6 Diesel - 242k miles
> > 2000 VW Golf 1.9TDI (turbo diesel) - 108k miles
> > AMSOIL Synthetic Lubricants Dealer #1098500
> > http://www.amsoil.com
> > 
> > ----- Original Message ----- 
> > From: "Scott Kair" <scott3491 at insightbb.com>
> > To: <Audi-VW-Diesels at yahoogroups.com>
> > Cc: <vwdiesel at audifans.com>
> > Sent: Monday, August 09, 2004 4:51 PM
> > Subject: [Vwdiesel] 92 ECO injectors
> > 
> > 
> > >     My 92 ECO 1.6 sortaTD has been experiencing gradually decreasing
> fuel
> > > economy and occasionally I see white exhaust puffs at startup after
> > sitting
> > > overnight. Fuel and coolant consumption is nil, and with 180k on the
> > clock,
> > > I suspect that it's time for new injectors.
> > >     The ECO injector needles and tips list different part numbers
> from
> > those
> > > of conventional 1.6 TDs.  I've got some old VW promotional material
> that
> > > says that the injector tips were changed in order to increase their
> > > longevity.  Unfortunately, my usual suppliers can't locate any new
> or
> > > rebuilt injectors, this model having sold only about 1000 units over
> 2
> > > years.  My question is whether conventional td injectors would be
> > acceptable
> > > for use in this application.  Break pressure on the ECO injectors is
> the
> > > same on either unit.
> > >     TIA,
> > >     Scott Kair
> > 
> > _______________________________________________
> > Vwdiesel mailing list
> > Vwdiesel at vwfans.com
> > http://www.audifans.com/mailman/listinfo/vwdiesel
> > 
> 
> _______________________________________________
> Vwdiesel mailing list
> Vwdiesel at vwfans.com
> http://www.audifans.com/mailman/listinfo/vwdiesel
> 
> 
> 