[Vwdiesel] A TDI tale of woe and strife, hammers and PBlaster

[The President]

Hi Hayden
Sounds like a bit of a nightmare you've just been through.
However you  seem to have opened a can of worms; but things are a little 
confusing...
for me heatshields over here from the stealershipwee far from a few cents in 
fact the were £10 for four!
The importance of replacing is  unclear from what you have posted because in 
your info you state that a  PO failed to even reuse  old ones.  I'm not sure 
that the sealing face of the injector will bottom out and seal before the 
threads run out without any shields. The shields are protectors of the 
threads from partial gas leaks and the dreaded carbon build up on the 
threads which makes the injectors become for good 'reamers'...  For the 
carbon to  build up inside the injector means that the needle isn't seating 
properly after each  squirt which is either from extreme wear or 
incompatible nozzle-needle seating .Someone on the GTD site claimed to reuse 
10 times or so each heatshield; by knowing how much deformation takes place 
(a few thou) and  using apress to reshape them
regards
Mark

>From: dieseltdi at verizon.net
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>Subject: [Vwdiesel] A TDI tale of woe and strife, hammers and PBlaster
>Date: Wed, 25 Jan 2006 19:36:05 -0600
>
>For those of you that may wonder why you must have the injector "heat  
>shields" (really just copper crush washers} and wonder why you can't  just 
>reuse the old ones....read on!  I have been working on the 1Z  engine that 
>I bought for my Caddy TDI conversion.  New belts, clutch,  hoses, the usual 
>stuff.  Well I also bought a set of high flow  nozzles and had them 
>installed in some injectors that I had laying  around.  I pulled the stock 
>injectors from my Jetta (they have been  in the car almost 80000 miles) to 
>install the high flow injectors to  see how they run.  The old injectors 
>slipped right out and the new  ones went right in no problems.  I drove 
>them for about 2 months and  then pulled them to install them in my donor 
>engine.  This seemingly  simple task has turned into the project from hell. 
>  I spent a WEEK  trying to pull the injectors out of the 1Z engine.  The 
>would not  come out!  I could get them to turn but it was the top of the  
>injector unscrewing from the nozzle section.  Finally out of  frustration, 
>I unscrewed the top of one completely, pulled out the  innards that I could 
>get and then filled the hole with PBlaster and  then waited a full week.  I 
>screwed the two halves together but still  NO GO!  I applied heat, I 
>applied more solvent, I beat up the  injectors with a hammer trying to 
>loosen them  NO GO!  Finally out of  frustration, I pulled the head, 
>definitely not what I really wanted  to do.  I then disassembled the 
>injectors (by now ruined anyway) and  used a punch to drive out the nozzles 
>which were absolutely caked  with carbon.  Fine I think, the nozzles are 
>out.  Well the nozzles  were out but not the bottom part of the injector 
>that holds the  nozzles.  After some more heating and putzing around with 
>it, I  reassembled the injector with the nozzle portion inside but upside  
>down to give me a flat surface inside the injector to push against.   Using 
>a old screw driver shaft with no handle, I put it through the  injector 
>hole into the injector and pounded the injectors out one at  a time.  It 
>took at least 5 good hits with a heavy framing hammer to  get each injector 
>loose.  Each one was caked with carbon and the  holes were caked with 
>carbon and guess what was missing?  No copper  washers!  Now I have to buy 
>a new head gasket and new stretch bolts  for the head (and expense I wasn't 
>counting on).  Moral of story, the  crush washers are cheap, do try to save 
>money by not replacing them  when you remove the injectors, you will regret 
>it later and make sure  to get the actual OEM washers.  Turns out most of 
>the after market  washers are too big and will not seal properly and the 
>keep the  injector from actually seating inside the cylinder.    Now to go 
>take  some tylenol for my old, aching shoulders.  hayden
>
>Visit my website at:  http://mysite.verizon.net/resosxp8/mydieselpages/
>Proud owner of:
>2004 Passat TDI GLS, 2.0l, 8 valve, 134 HP, 247 lb/ft of torque  (making 
>150 hp with Diesel Power Tuning Box), Blue Graphite,  Anthracite leather 
>interior, ABS, ESP.
>1998 Jetta TDI (Wetterauer Chipset, 2 1/2" exhaust, K&N Filter,  140K + 
>miles, and running biodiesel)
>1981 Rabbit Pickup -Awaiting a TDI engine swap with a 96 Passat 1Z  engine.
>And many, many, many VWs; from a 1946 Beetle (11 Beetles total), to  Vans 
>(5 - 3 splitties, 2 bay window), Rabbits (3), Karmen Ghia (1),  Jettas (5), 
>Passat (1), Dasher (1), New Beetle (1), and Rabbit  Pickups (3) most now 
>gone but not forgotten.
>1982 Suzuki GS 650GL - resurected from a farm, now back on the road,  Old 
>school bike for an old school guy!
>
>
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