United Diesel?

Darkside Developments, not sure if they do testing but worth a shot, they are in Barnsley.

 

Project power, he just did an amazing job on mine

http://www.project-power.co.uk/

 

How much did you pay Seatmann?

 

'get it fault code read at the timings all checked first before paying for someone to test them all'

 

Removed injectors 1 and 4 today, couldn't get 2-3 out. 1 and 4 were absolutely covered in carbon buildup though, it was all caked around one side of the nozzle, you could see where the spray was jetting through the carbon.

Cleaned those two off and refitted them, going to try and get 2 and 3 out when I make/find a slide-hammer.

The engine seems to sound more like a diesel now, less 'muted', has more 'clatter' than it did but sounds healthier.

Dave.

 

15mm spanner on the flats to twist it and one of the fuel pipes bolted on the top to pull on. Don't tighten the pipe fully up though.

It costs between £40-£50 depending on what you need done but I'm really chuffed with mine. I have the bigger nozzles and was needing them reset to different pressures to help with tuning. He did an awesome job on them, cleaned them to a spotless finish and then redid the pressures. You can see them on the last page of my build thread.

Once you've messed about with them you could try something like diesel purge to help further, not as good as someone taking them apart and doing it properly but it should help all the same.

 

Yea, I tried that and it was having none of it. you could just about hammer it left and right but there was absolutely no way it was going to come upwards.

I removed the injectors from the other engine, I thought it was a 90HP, turns out its actually a 110 as well, my memory is crap. Unfortunately The injectors are the 190/300 BAR types, not the 220/300 that my engine has fitted. They DO have good nozzles though, so if I can get 2 and 3 out then I might swap the nozzles over.

I don't mind taking them apart and changing the nozzles without a pop-test, I can't see the opening pressure changing unless you mess around with the springs and washers.

Dave.

 

Got my injectors out today, had to make up a tool to do it though, not a problem if you have some scrap and welding gear handy.

I Cut one end off an old VW droplink that was in the pile of crap to go to the tip, tapped an M10 thread onto the end, welded an M10 nut onto the injector pipe nut that I had to nick off the other engine.

Used a heavy 36mm Hub nut socket as the weight and slid this onto the rod, screwed the nut to the top of the injector, screwed the rod into the nut and then hammered upwards for about 2 minutes solid. #3 eventually came away, #2 wasn't as bad.

Both of the Inectors had been sealed in with hardened carbon deposits due to the copper rings not sealing properly, I had to clean the bores with a spinning wire brush and clean the outside of the injectors to get them in again.

When I had the injectors out I cleaned the worst of the carbon off with Ultrasolve (solvent cleaner) and shoved them in an ultrasonic cleaner with some Acetone to break down the carbon, this seemed to work ok but there was still stuff inside some of the jets, so I had to very gently prod them with a strand of copper wire to break up the carbon inside the holes.

As you can see from the pictures there was a lot of crap on the nose of the injectors initially.

After re-fitting them I have noticed a definite change, there's a little more power, not much but some. It's all at the bottom of the rev range, seems more torquey. After driving around a bit it looks like the MPG is coming back up, maybe 5-6MPG. I won't be able to tell for sure until I fill up next time.

Going to give it a Diesel purge next to see how that improves things.

Dave.

 

Diesel purge, advance the timing up near the top line in the graph in vagcom and maybe turn up the fuel.

Advancing the timing can help with starting, better burning of the fuel and it also stretches out the power so you get a bit more further up.

Cleaning the intake can help a lot too with the higher end.

Those injectors are in a hell of a state lol, god knows what's been going on there. Maybe the timing has been retarded a bit for a long time.

 

I'll have to be honest with you, I've no idea how to use vagcom properly.

Do you need the full edition or can you use the trial edition? which graph do you mean too? I don't recall seeing one for timing etc.

Yea, those injectors were obviously well knackered, they could probably still do with new nozzles but I'm not splashing out on those yet, genuine ones are about £30 a pop and I ain't gonna buy cheap copies.

Do you have to manually advance the timing using the pulley on the pump or is it done electronically?

 

Hi mate. I also have a 110 AHF and i live in newcastle so could help you out with the pump timing and vag com.

Derek

 

Hi Derek,

That could be good, I did the timing belt etc last year and I don't think I checked the timing any further than using the timing pins to line it all up.

Dave.

 

Hi Derek,

That could be good, I did the timing belt etc last year and I don't think I checked the timing any further than using the timing pins to line it all up.

Dave.

 

ah right then your timing will just be in the injection window. Where abouts in blyth do you live and when is best for yourself?

 

Here's a thing on timing, I'd stick up about 60-65 or so myself and try that. My guess would be that the timing has maybe been slightly retarded for a while and it's that that's caused the state of the injector nozzles.

http://forums.tdiclub.com/showthread.php?t=240450

 

Ok, I popped over to a mate's house and was telling him about my injectors and he told me he had Vagcom so I let him loose on my car.

He plugged in the computer and following the instructions on the TDIclub webpage we got the graph up, I got a bit worried as the car started shouting 'ENGINE WORKSHOP!' while vagcom was showing the graph, but it seems to be ok.

Anyway, here's the graph, the little box at the bottom appears to think that the timing is slightly advanced at '55', is this right?

Dave.

 

Yep, timing looks pretty good, a bit advanced is always a good thing.

That light always flashes with some things when using vagcom like timing for instance, nothing to worry about.

 

Right, so would you suggest just leaving it alone then? or is it worth advancing it more?

Cheers, Dave.

 

I'd probably leave it on standard injectors.

Any idea where the IQ is set? I don't suppose your mate checked that?

 

Nah, IQ wasn't checked, I'll be nipping back over either tonight or tomorrow though, what's the procedure for checking IQ?

Dave.

 

Tada!

http://www.myturbodiesel.com/1000q/multi/IQ-adjust-hammer-mod-TDI.htm

 

Ah, cheers man, I knew I'd seen that guide somewhere but couldn't find it!

Dave.

 

I nicked my mate's laptop for the day and followed the guide, the IQ was about 3 - 3.2 so I upped it slightly to 4mg. Seems to be a little more responsive and better at starting.

I'll see how it goes in the coming week.

Dave.

 

Sounds good, that's sort of where I would usually have the IQ

Are you going to run some diesel purge through the system? Should be the icing on the cake really lol

 

Yea, bought 500ml from ebay, should be here soon I think. I'm still amazed at the changes ive seen already, if I can get even more oomph with the diesel purge then bring it on!

I've started taking a bit more pride in the car after all this, actually got round to filling a dent and painting the rear arch yesterday. Something that's been bugging me for years.

Dave.