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

Thu Jan 26 17:22:18 EST 2006

Ha ha
You got me there! I was thinking 1.9TD. I was wondering how you were 
hammering them out!
How's that manual clutch doing?
Mark

>From: "Hayden Chasteen" <dieseltdi at verizon.net>
>To: "The President" <quantum-man at hotmail.co.uk>
>CC: <vwdiesel at www.audifans.com>
>Subject: Re: [Vwdiesel] A TDI tale of woe and strife, hammers and PBlaster
>Date: Thu, 26 Jan 2006 15:44:08 -0600
>
>Mark, the heat shields on the TDI are very different from those in the old 
>VW diesels.  The injectors do not screw into the head, instead they are 
>held in place by friction fit and a clamp.  The "heat shield" is really 
>only a copper crush washer that slides over the end of the injector nozzle 
>which, unlike the old diesels, actually projects down from the main 
>injector body. It is very different from the old style which, as you say, 
>help to prevent the gases from coming up into the threads.  The injector 
>nozzle tip of the TDI actually extends into the combustion chamber so there 
>must be a good seal between the combustion chamber and the injector body 
>otherwise the carbon and gases leak up and, as in my case, essentially weld 
>the injectors to the head.  hayden
>----- Original Message ----- From: "The President" 
><quantum-man at hotmail.co.uk>
>To: <dieseltdi at verizon.net>; <vwdiesel at vwfans.com>
>Sent: Thursday, January 26, 2006 3:21 PM
>Subject: RE: [Vwdiesel] A TDI tale of woe and strife, hammers and PBlaster
>
>
>>
>>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
>>>To: VW TDI Mail List <vw-tdi at yahoogroups.com>,tdi conversions news list 
>>>news list <TDI-conversion at yahoogroups.com>,VW diesel mail list 
>>><vwdiesel at www.audifans.com>,Audi-VW-diesels Mail list 
>>><audi-vw-diesels at yahoogroups.com>,VW Pickup Mail list 
>>><vwpickups at neubayern.net>
>>>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!
>>>
>>>
>>>_______________________________________________
>>>Vwdiesel mailing list
>>>Vwdiesel at vwfans.com
>>>http://www.audifans.com/mailman/listinfo/vwdiesel
>>
>>_________________________________________________________________
>>Don't just search. Find. Check out the new MSN Search! 
>>http://search.msn.click-url.com/go/onm00200636ave/direct/01/
>>
>

_________________________________________________________________
The new MSN Search Toolbar now includes Desktop search! 
http://toolbar.msn.co.uk/