1.6TD - pinhole leak in injector pipe!!! HELP

Post by **pimpdriver** » 15 Dec 2005, 23:24

Hi,

1988 E reg, 1.6 turbo diesel (JX), 5 speed. 162k miles.

Heard a funny noise tonight, when I put my foot down. It rose and fell in time with the engine, but was not as fast. A bit like a misfire, but all 70bhp in my panel van were there.

Took the engine cover off, there is a pinhole leak in one of the injector pipes (the one furthest forward, no. 4???)

See photo:

How dangerous is this?

What as caused it (erosion/corrosion???)

How should I solve it? (take the pipe off, take it somewhere and get a copy made, and put it back on?)

Or take it to my local friendly garage?

Should I change all 4 if they are going to be in a similar state to this?

I need the van for work on Monday, so am in urgent need of advice!

Thanks for any help guys (and gals)

Cheers,

Steve
Bristol

Post by **R0B** » 15 Dec 2005, 23:39

this has happened to me.you can order a new one from your local vw dealership..i doubt you will get one made up.i just replaced the one that had a hole in it.

Post by **pimpdriver** » 15 Dec 2005, 23:45

thanks for the speedy reply Rob. What sort of price is it (£5/£10/£50). Do I need to change any washers when I take it off, or does it come with new ones?

I have never taken one of these off before, but I have taken the Bosch K Jet fuel pipes off my Audi 100. Is it as simple as it looks, or is it one of those "oh my god I've almost done it but I can't get the last bolt undone" things, and should I take it to the garage while it is still in one piece?

Cheers,

Steve

Post by **R0B** » 15 Dec 2005, 23:50

sorry cant remember the cost of the replacement i dont think it was more than £20.00.its pretty easy to do yourself.cant remember the size of the nuts
but i do remember getting a ring spanner and cutting a slot into it this enables you to remove the nuts a bit easier..hope you understand what i mean..theres no washers to replace

Post by **R0B** » 15 Dec 2005, 23:53

its difficult to get an open ended spanner on some of the nuts.looking at yours you should be ok.the one that went on me was the one where the nut is underneath the others

Post by **guz** » 16 Dec 2005, 00:33

cracking piccie that.

Post by **pimpdriver** » 16 Dec 2005, 07:21

I thought it was quite a good piccy too!

Will try and effect a temporary repair with a jubilee clip, some bicycle inner tube and a cut up bit of coke can, then I am off to the main dealer with either the van (if the repair works) or a photo.

Any ideas to the cause, it is on the inner side of the bend so shouldn't be affected by erosion!

Steve

Post by **R0B** » 16 Dec 2005, 13:47

the diesel is under extremely high pressure going through these pipes so i doubt you will be able to repair it.a small flaw in the pipe could be the reason its sprung a leak.and with the high pressure the fuel has found its way out..

Post by TD » 16 Dec 2005, 19:57

don't repair it , or try! waste of time and loss of fuel(valuable)
if you have a BOSCH diesel specialist near you they will make one for £20+vat
they did for me
good idea to get new leak off pipes too , they crack and - well leak!
never put your skin near the leak, the pressure is so high it will penetrate your skin! - warning

Post by **pimpdriver** » 17 Dec 2005, 13:01

got a new pipe from VW for £33. Where would I get the leak off pipe from? A Bosch agent or a normal motor factors who sells fuel pipe etc?

Thanks for all your help,

Steve

Post by TD » 17 Dec 2005, 21:38

I used Bosch agent, as they are nearby. I presume it is standard stuff though that could be cut off a reel.
perhaps GSF have the stuff, or a local factor. This must be common.
but mine did crack and leak.

Post by **HarryMann** » 17 Dec 2005, 22:27

never put your skin near the leak, the pressure is so high it will penetrate your skin! - warning

Good warning TD!

Cannot fix at such pressures unless take off and braze/ silver solder when clean, and that unlikley and dangerous as leak caused by corrosion where pipe originally was bent on mandrel (probably)..

Post by **Diamond Hell** » 18 Dec 2005, 01:21

Sorry, I've been away for a couple of days and I have some 1.6TD injector pipe sets lying around - would have been pleased to help out.

If you need any help with it advice etc do come round some time - I've got a bit of experience of living with diesels. I'm in Filton and I'll PM you my number.

Post by **pimpdriver** » 18 Dec 2005, 17:12

Hello one and all,

Fitted the new pipe in about 4.5 minutes. Solved that problem.

However, the noise is still there, so I will put a new post to keep it relevant.

Thanks,

Steve